The Australian Welding Guide 2012

1
THE AUSTRALIAN
WELDING
GUIDE
welding.com.au
The Ultimate Welding
Reference Guide 2012
2 welding.com.au 1300 300 884
FOR OVER 50 YEARS
With a proven history of over 50 years in the Australian market,
WIA has built a reputation for delivering high quality fller
metal products for the industrial user. Known for their quality,
consistency and performance, WIA fller metal products are
preferred by operators across a wide range of industry sectors.
WIA offers an extensive range of consumables for various
welding processes and applications. Choose from mild
steel and low hydrogen electrodes to specialised fux cored
wires and hardfacing products.
Backed by a team of technical professionals who understand
our customers needs, we are committed to delivering
welding products that offer peak performance in operability,
mechanical properties and productivity, and backed by the
delivery of technical expertise and support.
WIA is ISO 9001 certifed. Its your guarantee of the highest
levels of quality, satisfaction and effciency when you
choose WIA products.
1
WELDING
INDUSTRIES
OF AUSTRALIA
AN ITW COMPANY
USING THIS GUIDE
PRODUCT SECTION
The front section of this guide contains comprehensive product
information on the range of WIA consumables. Access the latest
information on WIA fller metal products, including technical data
sheets at welding.com.au.
TECHNICAL REFERENCE SECTION
Designed as a portable reference tool for welding engineers, design
and costing personnel, workshop supervisors, welding specialists
and students, the Technical Reference Section incorporates the
information welding professionals need to have on hand.
VIEWING THIS GUIDE AS AN INTERACTIVE PDF
Depending on the device or computer you are viewing this PDF in,
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DISCLAIMER - Welding Industries of Australia (WIA) is a supplier of welding products,
and does not operate as a provider of consultancy or other technical services or advice
related to welding. The information provided in this document is offered as a guide only.
Every effort has been made to ensure the information contained in this booklet was
correct at the time of printing. WIA does not accept responsibility for errors or information
which is found to be misleading. Prior to using WIA products, it is the purchasers
responsibility to ensure the products selected are suitable for the application.
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3
INTRODUCTION

ELECTRODES
General Purpose Electrodes - Mild Steel
Hydrogen Controlled Electrodes
Iron Powder Electrodes
Cellulose Electrodes
Stainless Steel Electrodes
Cast Iron Electrodes
Gouging and Cutting Electrodes

WIRES
Solid MIG Wires Mild Steel
Solid MIG Wires Low Alloy Steel
Solid MIG Wires Aluminium
Metal Cored Gas Shielded Wires
Flux Cored Gas Shielded Wires
Flux Cored Self Shielded Wires
HARDFACING PRODUCTS
Hardfacing Electrodes
Hardfacing Solid MIG Wires
Hardfacing Self Shielded Flux Cored Wires
Hardfacing Gas Shielded Flux Cored Wires
TECHNICAL INFORMATION
5
1
CONTENTS
33
65
86
5
GENERAL PURPOSE ELECTRODES - MILD STEEL
Austarc 12P ................................................................ 6-7
Austarc 13S ................................................................ 8-9
HYDROGEN CONTROLLED ELECTRODES
Austarc 16TC ...........................................................10-11
Austarc 18TC .......................................................... 12-13
Austarc 77 ............................................................... 14-15
IRON POWDER ELECTRODES
Austarc 24 ............................................................... 16-17
CELLULOSE ELECTRODES
Austarc 11 ............................................................... 18-19
STAINLESS STEEL ELECTRODES
Staincord 309Mo-16 ................................................ 20-21
Staincord 316L-16 ................................................... 22-23
Unicord 312 ............................................................ 24-25
CAST IRON ELECTRODES
Supercast Ni ........................................................... 26-27
Suercast Ni/Fe ........................................................ 28-29
GOUGING AND CUTTING ELECTRODES
Austarc C&G ........................................................... 30-31
ELECTRODES
CONTENTS
CONTENTS
6
CONTENTS
AUSTARC 12P
SUMMARY
General Purpose Rutile Type Electrode
Versatile/All Positional Capabilities Including Vertical Down
Smooth Performance on Low OCV AC Welding Machines

IDENTIFICATION
Coating - Brown Tip - Red Imprint - WIA 4313A

CLASSIFICATION
AS/NZS 4855-B - E43 13 A
AWS A5.1: E6013

DESCRIPTION AND APPLICATION
Austarc 12P is a smooth running, rutile type electrode for
all positional welding of mild steel. It is characterised by a
moderately forceful and extremely stable arc. Superb arc
starting and restriking on low voltage AC welding machines.
A stiff fast freezing slag for all positional (especially vertical
down) fllet welding capabilities. Typical applications include,
the all positional welding of galvanised gates/fences, steel
furniture, trailers and wrought iron.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
2.0 300 40-60 19
2.5 300 60-85 20
3.2 380 90-130 21
4.0 380 130-180 22
5.0 450 180-230 23
*Recommended for DC +/- or AC (minimum 45 OCV) operation.
**Voltage is determined by arc current and electrode arc length.
Arc voltage shown is typical and is only to be used as a guide.
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CONTENTS
SHIPPING APPROVALS
LR 2Ym ABS 2 DNV 2
TYPICAL ALL WELD METAL CHEMICAL ANALYSIS
C Mn Si Fe
0.07 0.5 0.3 Bal

TYPICAL ALL WELD METAL MECHANICAL ANALYSIS
Yield Stress 450 MPa
Tensile Strength 500 MPa
Elongation 26%
CVN Impact Values 70J @ 0C
In as welded condition.
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS PER
KG
PART
NUMBER
Packet Carton
2.0 2.5 12.5 103 12P20
2.5 2.5 12.5 67 12P25
3.2 5.0 15 31 12P32
4.0 5.0 15 20 12P40
5.0 5.0 15 11 12P50

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CONTENTS
AUSTARC 13S
SUMMARY
General Purpose/Rutile Type Electrode
Versatile/All Positional (especially vertical up) Capabilities
Ideal for Down Hand Fillet Welding of Mild Steel

IDENTIFICATION
Coating - Blue/White Stripe Tip - Plain Imprint - WIA 4313A

CLASSIFICATION
AS/NZS 4855-B - E43 13 A
AWS A5.1: E6013

Austarc 13S is the popular blue and white striped general
purpose electrode for smooth mitre fllet welding applications.
13S has a soft and stable arc and produces fat, uniform fllet
welds with ease and a self peeling slag action.
Austarc 13S is formulated primarily for fllet welding in all
down hand positions. It is ideal for the general purpose and
structural welding of sheet and plate steels (galvanised or
otherwise) and tubular components, including trailers, duct
work, hoppers and storage tanks, etc.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
2.0 300 40-60 19
2.5 300 60-85 20
3.2 380 100-130 21
4.0 380 140-180 22
5.0 450 180-230 23
6.0 450 230-290 24
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CONTENTS
SHIPPING APPROVALS
LR 2m ABS 2 DNV 2
C Mn Si Fe
0.07 0.55 0.45 Bal

Elongation 26%
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS PER
KG
PART
NUMBER
Packet Carton
2.0 2.5 12.5 99 13S20
2.5 2.5 12.5 63 13S25
3.2 5.0 15 29 13S32
4.0 5.0 15 10 13S40
5.0 5.0 15 6 13S50
6.0 5.0 15 6 13S60

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CONTENTS
AUSTARC 16TC
SUMMARY
Basic/Twin Coated (TC) Manual Arc Electrode
Low Hydrogen, H10 Status
Versatile/All Positional (Especially Vertical Up) Capabilities
Reliable, Low Temperature Impact Toughness
Easy to Strike and Re-Strike

IDENTIFICATION
Coating - Light Grey Tip - Bronze Imprint - WIA 4916A

CLASSIFICATION
AS/NZS 4855-B - E49 16-A U H10
AWS A5.1: E7116-1 H8

Austarc 16TC is a smooth running, basic low hydrogen electrode,
developed for all positional (except vertical down) welding, using
AC or DC power sources. The electrode gives exceptional arc
stability and weldability for its class and produces high quality weld
deposits with reliable notch toughness to -40C. Austarc 16TC is
manufactured using a unique twin coating extrusion process, which
produces electrodes with two concentric fux coatings. Arc stabilising
elements are concentrated in the inner coating of the electrode for
signifcantly improved arc stability on AC welding machines.
Other features of 16TC include, a smooth rippled weld profle with
excellent edge wetting and a fuid, easily removed glassy slag. Austarc
16TC deposits X-ray quality weld metal with typical diffusible
hydrogen levels of 5-8 mls of hydrogen per 100 gms of deposited
weld metal, for as manufactured product, thus satisfying the H10
low hydrogen category of AS/NZS 4855 and H8 of AWS A5.1.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
2.5 300 60-90
3.2 380 90-135
4.0 380 140-190
5.0 450 190-240
6.0 450 250-310
*Please note, 2.5 and
3.2 Austarc 16TC are
recommended for
DC+ or AC (minimum
45 OCV) operation,
whereas 4.0, 5.0 and
6.0mm sizes require a
minimum of 55 OCV for
stable AC operation.
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CONTENTS
SHIPPING APPROVALS
LRS 4Ym H10 ABS 3 H10 DNV 3Y H10
C Mn Si P S Fe
0.06 1.2 0.4 0.015 0.010 Bal

Elongation 28%
CVN Impact Values 130J @ -20C 110J @ -40C
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
2.5 2.5 12.5 61 16TC25
3.2 5.0 15 29 16TC32
4.0 5.0 15 19 16TC40
5.0 5.0 15 10 16TC50
6.0 5.0 15 7 16TC60

MATERIALS TO BE WELDED
CODE TYPE
Structural
Steel
AS 1163 C250, C350, C450
AS 1397 G250, G300, G350, G450
AS 1450 C/H200, C/H250, C/H350, C/H450,
AS/NZS 3679.1 250, 300, 350, 400
AS/NZS 3678.1
AS/NZS 3679.2
200, 250, 300, 350, 400, 450,
A1006, XK1016, WR350
Pressure
Equipment
Steel
AS 1548 7-430, 7-460, 5-590, 7-490
Fine Grain
Steel
AS/NZS 1594
HAI, HA3, HA4N, HA200, HA250,
HA300, HA1006, HA1010, HA1016,
HA350, HA400
Cast Steel AS2074 C2, C3, C7A-1, C1, C4-1, C4-2, C7A-2
Pipe Material API 5LX X42, X46, X52, X60
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CONTENTS
AUSTARC 18TC
SUMMARY
Basic Twin-Coated (TC) Iron Powder Electrode
Very Low Hydrogen H5 Status
Suitable for all Positional Welding Except Vertical Down
Excellent Low Temperature Fracture Toughness
Easy to Strike and Re-Strike

IDENTIFICATION
Coating - Light Grey Tip - Blue Imprint - WIA 4918-1A

CLASSIFICATION
AS/NZS 4855-B - E49 18-A U H5
AWS A5. 1: E7018-1

Austarc 18TC is a basic iron powder electrode used primarily on
C-Mn and low alloy structural steels. The unique twin-coat design
for 18 type low hydrogen electrode offers excellent AC arc stability
and superb DC+ arc transfer, excellent re-strike, reduced spatter
level and extraordinary ease of use for out-of-position welding.
Typical applications include oil and gas, pipe welding, structural
steel construction, off-shore where Ni-alloying is prohibited,
mining equipment, heavy girders and earth moving plant repair
and maintenance.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
2.5 300 60-90
3.2 380 90-135
4.0 380 140-190
*Please note, the recommended welding polarity for
Austarc 18TC is DC + or AC (Min. 50 OCV).
SHIPPING APPROVALS
LRS/Pending DNV/Pending
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CONTENTS
C Mn Si P S Fe
0.06 1.55 0.54 0.010 0.02 Bal

Elongation 24%
CVN Impact Values 87J @ -50C
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
2.5 2.5 12.5 45 18TC25
3.2 5.0 15 26 18TC32
4.0 5.0 15 17 18TC40
MATERIALS TO BE WELDED
CODE TYPE
Structural
Steel
AS 1163 C250, C350, C450
AS 1397 G250, G300, G350, G450
AS 1450 C/H200, C/H250, C/H350, C450
AS 1450 250, 300, 350, 400
C/H200, C/
H250,
200, 250, 300, 350, 400, 450,
A1006, XK1016, WR350
AS/NZS 3679.1 250, 300, 350, 400
AS/NZS 3678.1
AS/NZS 3679.2
200, 250, 300, 350, 400, 450,
A1006, XK1016, WR350
Pressure
Equipment
Steel
AS 1548 7-430, 7-460, 5-590, 7-490
Fine Grain
Steel
AS/NZS 1594
HA1, HA3, HA4N, HA200, HA250,
HA300, HA1006, HA1010, HA1016,
HA350, HA400
Cast Steel AS2074
C2, C3, C7A-1, C1, C4-1, C4-2,
C7A-2
Pipe Material API 5LX X42, X46, X52, X60
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CONTENTS
SUMMARY
Basic Coated Iron Powder Electrode
Low Hydrogen Status
Suitable for All Positional Welding Except Vertical Down
Excellent Low Temperature Fracture Toughness

IDENTIFICATION
Coating - Light Grey Tip - Black Imprint - WIA 4918-1A

CLASSIFICATION
AS/NZS 4855-B - E49 18-1 U H5
AWS A5.1: E7018-1

The Austarc is a smooth running basic type of low hydrogen
iron powder electrode used for all positional welding except
vertical down. The arc is very quiet with little spatter and the
welds are exceptionally smooth with excellent wash in at the
toes of the weld, thus giving minimum undercut. This electrode
is used where the highest restrained work pieces are fabricated
for mining equipment, pressure vessels, heavy girders, earth
moving plant, repair and maintenance etc.
For the highest weld quality with low hydrogen levels, Austarc
77 electrodes should be baked at 400C for one hour to obtain
<5mL/100g weld metal. After baking, the electrodes should be
used from a hot box set at 100 -150 C.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
2.5 305 60-105 20
3.2 380 90-145 22
4.0 380 140-200 24
5.0 455 180-300 26
AUSTARC 77
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CONTENTS
SHIPPING APPROVALS
LR 4Ym H5 ABS 3Y H5
C S Mn P Si Fe
0.05 0.011 1.28 0.022 0.30 Bal

Elongation 30%
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS PER
KG
PART
NUMBER
Packet Carton
2.5 2.2 11 45 7725
3.2 5.0 15 26 7732
4.0 5.0 15 17 7740
5.0 5.0 15 9 7750

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CONTENTS
SUMMARY
High Iron Powder, Rutile Type Electrode
High Deposition Rates and Effciencies
Suitable for Fast Downhand Fillet and Butt Welding

IDENTIFICATION
Coating - Brown Tip - Yellow Imprint - WIA 4924A

CLASSIFICATION
AS/NZS 4855-B - E49 24 A
AWS A5.1: E7024

Austarc 24 is a high iron powder, rutile type electrode designed
for the fast down hand welding of mild steel using AC or DC power
sources. Features include high deposition rates/effciencies and
fat to slightly concave fllet welds with excellent edge wash and
slag detachability. With its smooth running, positive re strike and
high current carrying capacity, Austarc 24 is the ideal fllet welding
electrode for down hand positions aimed at higher productivity.
Austarc 24 is suited to long, heavy fllet and butt welding
applications using a touch welding or `short arc technique.
Such applications include the production welding of tanks,
structural members/frames and truck and tractor bodies etc.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
3.2 380 120-170 24
4.0 450 200-240 25
5.0 450 270-320 26
AUSTARC 24
17
CONTENTS
SHIPPING APPROVALS
LR 2Ym ABS 2 DNV 2
C Mn Si Fe
0.06 0.7 0.4 Bal

Elongation 27%
In as welded condition
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS PER
KG
PART
NUMBER
Packet Carton
3.2 5.0 15 18 2432
4.0 5.0 15 12 2440
5.0 5.0 15 6 2450

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CONTENTS
SUMMARY
High Cellulose Coating
All Positional/High Penetration
Ideal for Site Welding

IDENTIFICATION
Coating - White Tip - Brown Imprint - WIA 4311A

CLASSIFICATION
AS/NZS 4855-B - E4311A
AWS A5.1: E6011


Austarc 11 is a high cellulose electrode developed for all
positional welding on both AC and DC power supplies.
Features include: Forceful, deep penetrating arc with
fast freezing slag. Particularly suited for vertical and incline
pipe welding where complete root penetration is required.
The thin brittle slag is easily removed.
Austarc 11 is recommended for specifc applications including
pipeline welding and storage tank construction where either
the Stove Pipe or Flick techniques can be used to obtain
full root penetration in critical structural joints.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
2.5 300 60-95 20
3.2 380 90-125 21
4.0 380 115-175 22
5.0 450 160-220 23
AUSTARC 11
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CONTENTS
SHIPPING APPROVALS
LR 3M ABS 3
C Mn Si Fe
0.13 0.5 0.1 Bal

Elongation 32%
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS PER
KG
PART
NUMBER
Packet Carton
2.5 2.5 12.5 66 1125
3.2 5.0 15 33 1132
4.0 5.0 15 21 1140
5.0 5.0 15 14 1150

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CONTENTS
SUMMARY
All Positional, Rutile Type Stainless Steel Electrode
Moisture Resistant Flux Coating/Extra Low Carbon Deposit
Suitable for the Dissimilar Welding of Stainless Steel to
Mild/Low Alloy Steels.

IDENTIFICATION
Coating - Grey Tip - Black Imprint - WIA 309MO-16

CLASSIFICATION
AS/NZS 4854-B - E309LMo-16
AWS A5.4: E309MoL-16


Staincord 309Mo-16 is an extra low carbon, rutile type electrode
exhibiting superior all positional (except vertical down performance
with an improved moisture resistant coating for weld metal of
high radiographic integrity. The smooth arc action of Staincord
309Mo-16, together with low spatter and excellent slag control/
detachability, promotes exceptional weld appearance and profle.
Staincord 309Mo-16 is a Molybdenum bearing, highly alloyed
23Cr/12Ni/2.5Mo stainless steel electrode for welding matching
309 and 309Mo base metals. Major applications of Staincord
309 Mo-16 also involve the welding of a wide range of 300
and 400 series stainless steels to mild/low alloy steels. 309M
is also suitable for general welding applications with alloyed
and non-alloyed dissimilar ferrous metal combinations.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
2.5 300 50-75 22
3.2 350 75-110 26
4.0 350 110-150 28
STAINCORD 309Mo-16
21
CONTENTS
C Mn Si Cr Ni Mo Fe
0.025 0.8 0.7 23.5 13.0 2.4 Bal

Elongation 38%
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
2.5 2.5 12.5 86 SC309MO25
3.2 2.5 12.5 55 SC309MO32

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CONTENTS
SUMMARY
All Positional, Rutile Type Stainless Steel Electrode
Moisture Resistant Colour Coated Flux Coating
Extra Low Carbon Weld Deposit
For the Critical Welding of Matching Type 316 and 316L Steels

IDENTIFICATION
Coating - Pink Tip - Green Imprint - WIA 316L-16

CLASSIFICATION
AS/NZS 4854-B - ES316L-16
AWS A5.4: E316L-16

New generation Staincord 316L-16 is an extra low carbon, rutile
type electrode exhibiting superior all positional (except vertical
down) performance with an improved moisture resistant Pink
fux coating for weld metal of high radiographic integrity. The
smooth arc action of Staincord 316L-16, together with low spatter
and excellent slag control/detachability, promotes exceptional
weld appearance and profle. Other features include high arc
stability and easy restriking on low voltage AC welding machines.
Staincord 316L-16 deposits Molybdenum bearing, 19Cr/12Ni/2.5Mo
fller metal to meet the requirements for welding type 316 and 316L
stainless steels in critical applications. Staincord 316L-16 is also
recommended for the general purpose welding of common 300
series stainless steels, such as 301, 302, 304 and 304L. It is also
suitable for the general welding of ferritic stainless steel alloys,
such as 409, 444 and 3Cr12.
STAINCORD 316L-16 STAINCORD 316L-16
23
CONTENTS
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
2.0 300 30-50 20
2.5 300 50-75 21
3.2 350 75-110 26
C Mn Si Cr Ni Mo Fe
0.025 0.7 0.7 18.5 12.0 2.4 Bal

Elongation 40%
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS PER
KG
PART
NUMBER
Packet Carton
2.0 2.5 12.5 86 SC31620
2.5 2.5 12.5 55 SC31625
3.2 2.5 12.5 27 SC31632

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CONTENTS
SUMMARY
Universal AC/DC Maintenance Electrode for
Welding Ferrous Metals
Ideal for Joining Dissimilar Steel Components
Suitable as a Buffer Layer Prior to Hard Surfacing
Stable Performance on Low OCV Welders

IDENTIFICATION
Coating - Grey Tip - Red Imprint - Unicord 312

CLASSIFICATION
AS/NZS 4854-B - ES312-16
AWS A5.4: E312-16


Unicord 312 is a basic, rutile type electrode depositing a
29%Cr/9%Ni stainless steel weld metal for the high strength
welding of a wide range of alloy steels and dissimilar ferrous
metals. The high ferrite, austenitic stainless steel deposit has
excellent resistance to hot cracking, even under dilution by
high carbon, alloy and tool steels. Unicord 312 is a universal
maintenance electrode combining high strength, toughness, wear
and corrosion resistance with compatibility to most ferrous metals.
Unicord 312 is suitable for many repair and maintenance
applications on steels of unknown composition. It is an ideal
electrode for welding medium to high carbon steels, low alloy
steels and dissimilar ferrous metal combinations. Unicord 312
is also suitable as a buffer or intermediate layer prior to the
application of hard surfacing.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
2.5 300 50-75 22
3.2 350 75-110 26
*Recommended for DC +/- or AV (minimum 45 OCV) operation.
UNICORD 312
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CONTENTS
C Mn Si Cr Ni Fe
0.04 0.9 0.85 30.0 9.0 Bal

Elongation 45%
Deposit Hardness 28-35 HRc
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
2.5 2.5 12.5 52 UC31225
3.2 2.5 12.5 27 UC31232

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CONTENTS
SUMMARY
Pure Nickel Core Wire/Basic, Graphite Coating
Soft Machineable Nickel Deposit for the Lower Strength
Welding of Cast Irons

IDENTIFICATION
Coating - Black Tip - Plain Imprint - WIA SC Ni

CLASSIFICATION
AWS A5.15: ENi-Cl


Supercast Ni is a basic, graphite coated AC/DC electrode for the
lower strength welding of cast irons. It is characterised by a soft,
smooth arc with low penetration and spatter levels on both AC
and DC power sources. Ease of striking is a feature of Supercast
Ni and it also has a particularly good wetting action resulting in
well bonded welds of regular contour and attractive appearance.
This electrode is made from a pure nickel core wire and
produces a ductile, fully machineable weld deposit. Supercast
Ni may be used for the repair and reclamation of all standard
grades of grey cast iron, malleable iron, austenitic cast iron
and some grades of mechanite cast iron.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
3.2 350 50-100 23
SUPERCAST Ni
27
CONTENTS
Mn Ni S Fe
0.3 97.0 0.006 Bal

Deposit Hardness 150-170 HV (30)
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
3.2 2.5 12.5 37 SNI32

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CONTENTS
SUMMARY
Nickel -Iron Core Wire/Basic, Graphite Coating
Machineable Nickel-Iron Deposit for the Higher Strength
Welding of Cast Irons, Particularly SG Irons

IDENTIFICATION
Coating - Black Tip - Green Imprint - WIA SC NiFe

CLASSIFICATION
AWS A5.15: ENiFe-Cl


Supercast Ni/Fe is a basic, graphite coated AC/DC electrode
for the higher strength welding of cast irons. It is characterised
by a soft, smooth arc with low penetration and spatter levels on
both AC and DC power sources. Ease of striking is a feature of
Supercast Ni/Fe.
This electrode is made from a Nickel-Iron core wire and
produces a ductile, machineable weld deposit with the extra
strength required for welding SG (Spheroidal Graphite) irons.
Supercast Ni/Fe may also be used for the repair and reclamation
of all standard grades of grey cast iron, malleable iron, austenitic
cast iron and some grades of mechanite cast iron. It is ideally
suited to the dissimilar welding of these irons to steels.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
3.2 350 50-100 23
SUPERCAST Ni/Fe
29
CONTENTS
Mn Ni S Fe
0.85 57.8 0.007 Bal

Deposit Hardness 200-220 HV (30)
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
3.2 2.5 12.5 39 SNIFE32

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CONTENTS
SUMMARY
Heavy Coated Manual Electrode for Cutting, Gouging
or Piercing Steels

IDENTIFICATION
Coating - Black End Tip - Plain

Austarc C&G is a heavy coated electrode providing a highly
mobile means of cutting, gouging and piercing most steels,
using standard AC or DC arc welding equipment. Austarc C&G
produces a very high arc force and can be used for general
cutting and grooving in joint preparation, removing defective
welds and reclaiming scrap metal, etc.
Oxy-acetylene and carbon arc-air cutting and gouging are two
processes available to industry capable of giving high quality,
smooth preparations. Austarc C&G will not replace these
processes but rather provide a convenient, easy to use and
mobile tool for the arc gouging and cutting of most metals.
It is particularly useful to the maintenance welder operating in
awkward locations to remove welds, open up joints and trim
off bolt or rivet heads, etc. Similarly, the rural welder will fnd
C&G handy in repairing or preparing joints when operating
away from (or without) oxy-acetylene equipment.
Cutting - Direct the electrode into the work in the desired cutting
direction, working from the outside edge. Use an up and down
sawing motion, the up arc length being increased to increase
heating, the down arc length being decreased to contact point
to force the molten metal out of the groove. Angle of electrode
should be approx 70 to the horizontal.
AUSTARC C&G
31
CONTENTS
Gouging - Point the electrode in the direction of gouging at
approx 10-20 to the plate surface. Strike the arc and move
forward rapidly. If slag and molten metal start to clog the groove
bring the electrode up to clear and, without breaking the arc, circle
backwards and move forward again. This latter technique may
prove more necessary than straight forward motion on lower
amps or as the electrode becomes hotter. If amps are excessive,
C&G will tend to cut out on AC and overheat, causing premature
charring of the coating and reduced arc force.
Piercing - For holes, plunge the electrode into the plate at slightly
off right angles. With a small circular motion to the holder, force
the electrode into the plate until full penetration is achieved.
Once the hole has been made it may be trimmed with an up
and down sawing motion.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
PACKAGING (KG)
WELDING CURRENT
RANGE *(A)
Packet Carton
3.2 380 4 12 170-250
4.0 380 4 12 220-350
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33
SOLID MIG WIRES
Austmig ES6 ...................................................................... 34-35
SOLID MIG WIRES - LOW ALLOY STEEL
Austmig ESD2 ........................................................ 36-37
Austmig NiCrMo ..................................................... 38-39
SOLID MIG WIRES - ALUMINIUM
Austmig 5183 .......................................................... 40-41
Austmig 5356 ......................................................... 42-43
METAL CORED GAS SHIELDED WIRES
Austfl 70C-6M ........................................................ 44-45
FLUX CORED GAS SHIELDED WIRES
Austfl 71T ............................................................... 46-47
Austfl 71T-1M ......................................................... 48-49
Hobart XL-525 ........................................................ 50-51
TM-71HYD .............................................................. 52-53
TM-811N2 ............................................................... 54-55
FLUX CORED SELF SHIELDED WIRES
Fabshield 4 ............................................................. 56-57
Fabshield 23 ........................................................... 58-59
Fabshield 21B ......................................................... 60-61
Fabshield XLR-8 ..................................................... 62-63
WIRES
CONTENTS
CONTENTS
34
CONTENTS
SUMMARY
Electrostatically Copper Coated Gas Metal Arc (MIG) Wire
All Positional Welding of Mild and Medium Strength Steels
Precision Layer Wound, Very Low Diffusable Hydrogen
Suitable for all Transfer Modes
Designed for use with Argon/CO
and CO
Shielding Gases

CLASSIFICATION
AS/NZS 2717.1: ES6-GC-W503AH
AS/NZS 2717.1: ES6-GM-W503AH
AWS A5.18: ER70S-6


Austmig ES6 is a copper coated, low carbon steel GMAW wire,
formulated for optimum performance under Argon/CO
mixed
gases and welding grade CO
. Arc transfer characteristics are

excellent with Argon based gas mixtures, particularly in spray
and pulsed transfer modes. Austmig ES6 is an electrostatically
copper coated wire providing excellent wire feeding and electrical
conductivity and reducing contact tip wear. The higher manganese
and silicon content of Austmig ES6 provides effective weld metal
deoxidation for resistance to porosity.
Austmig ES6 is suitable for a wide range of welding applications
on mild and medium strength steels providing consistently very
low H5 weld metal diffusible hydrogen levels when used with
suitable shielding gases.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
0.6 40-100 12-16
0.8 60-180 14-22
0.9 70-230 15-26
1.0 100-290 16-29
1.2 120-350 18-32
1.6 160-390 18.34
Welding Current DC +
*Voltage is determined by arc current and electrode arc length.
Welding currents and voltage shown are operational guides only.
AUSTMIG ES6
35
CONTENTS
SHIPPING APPROVALS
LR 3S, 3YS
C Mn Si S P Fe
0.1 1.45 0.88 0.02 0.022 Bal

Gas Type CO
Ar+18% CO
Yield Stress 460 MPa 480 MPa

Tensile Stress 560 MPa 580 MPa
Elongation 28% 26%
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
0.6
5kg spool
15kg spool
ES606M5KG
ES606S
0.8
5kg spool
15kg spool
ES608M5KG
ES608S
0.9
5kg spool
15kg spool
ES609M5KG
ES609S
1.0 15kg spool ES610S

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CONTENTS
SUMMARY
Copper Coated, High Manganese-Molybdenum Gas Metal
Arc (MIG) Welding Wire
For the all Positional Welding of Medium to Higher
Strength Steels

CLASSIFICATION
AS/NZS 2717.1: ESD2-GC-W559AH
AS/NZS 2717.1: ESD2-GM-W559AH
AWS A5.18: ER80S-D2

Austmig ESD2 is a copper coated, low alloy steel wire used
for welding medium to higher strength steels, particularly where
service temperatures up to 500C are encountered. ESD2 gives
excellent resistance to porosity using CO
or Argon based gas

mixtures (i.e. Ar/CO
, Ar/O
, Ar/CO
/O
). When porosity is a
potential problem due to dirty or rusty surfaces or higher than
normal sulphur contents, Austmig ESD2 will provide a
consistently sound weld deposit.
Austmig ESD2 is also suitable for out-of-position welding due
to its quick freezing weld pool. ESD2 produces high quality
welds on plain carbon and C-Mn steels, low alloy steels and
higher strength used in pressure vessels and boilers, such as
petrochemical and power generation industries, operating at
elevated temperatures. Austmig ESD2 may also be used for the
fllet welding of higher tensile, quenched and tempered steels,
such as Bisalloy 70 and 80 where the lower strength weld metal
may be compensated by larger fllet sizes.
When used with suitable shielding gases, Austmig ESD2
will consistently produce very low H5, weld metal diffusible
hydrogen levels, for excellent resistance to HAZ or hydrogen
induced cracking.
AUSTMIG ESD2
37
CONTENTS
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
0.9 70-230 15-26
1.2 120-350 18-32
C Mn Si Mo Fe
0.1 1.95 0.75 0.5 Bal

Gas Type CO
Ar+18% CO
Yield Stress 560 MPa 570 MPa

Tensile Stress 645 MPa 660 MPa
Elongation 19% 20%
NOTE: The use of less oxidizing Argon based gas mixtures will result
in higher manganese and silicon weld metal recovery, leading to higher
tensile properties, particularly in heavy multi pass butt welds.
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
0.9 15kg spool ESD209S
1.2 15kg spool ESD209S

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CONTENTS
SUMMARY
Copper Coated, Low Allloy Gas Metal Arc (MIG) Welding Wire
All Positional Welding of Medium and High Strength Steels
Welded Strength 760 MPa Tensile Class

CLASSIFICATION
AS/NZS 2717.1: ESMG-GM-W769AH-G
AWS A5.28: ER110S-G

Austmig NiCrMo is a copper coated, low alloy solid wire
suitable for the all positional welding of high strength steels
using Argon + CO
gas mixtures.
Austmig NiCrMo is ideal for the full strength welding of
quenched and tempered structural steels, of the 760 MPa
tensile class, such as USS-T1, CcMo Pipe, Welten 80,
Weldox 700, X80, N-A-XTRA and Bisplate 80.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
0.9 70-230 15-26
1.2 120-350 18-32
NOTE: Austmig NiCrMo is NOT to be used in weldments which
are to be stress relieved.
AUSTMIG NiCrMo
39
CONTENTS
C Mn Si Ni Cr Mo V Fe
0.07 1.22 0.37 1.42 0.29 0.24 0.07 Bal

Gas Type Ar+18% CO

Tensile Stress 799 MPa
Elongation 18%
NOTE: The use of less oxidizing argon based gas mixtures
(ie Ar/O
, Ar/CO
, Ar/CO
/O
), will result in higher alloy recovery

in the weld metal, leading to higher tensile properties.
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
0.9 15kg spool MNICRMO09S
1.2 15kg spool MNICRMO12S

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CONTENTS
SUMMARY
Aluminium-Magnesium-Manganese, Metal Inert
Gas (MIG) Welding Wire
Precision Layer Wound and Double Shaved for
Superb Feedability
For Welding of Alloys of the same Composition

CLASSIFICATION
AS/NZS ISO 18273 - S AI 5183
AWS A5.10: E5183

Austmig 5183 is a precision layer wound aluminium wire
alloyed with Mg, Mn and Cr.
It is recommended for welding Al/Mg material of the 5083 type
in the annealed condition, particularly for low temperature
applications where good ductility and toughness are required, ie
cryogenic plant. It may also be used for welding medium strength
Al/Zn/Mg alloys of the 7020 type and joining 5083 alloy to 5456 alloy.
Welding grade Argon or Argon/Helium shielding gas combinations
are recommended with fow rates of 10-20 litres/minute.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 150-250 20-27
1.6 200-350 23-30
AUSTMIG 5183
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CONTENTS
SHIPPING APPROVALS
LR WC/1-1S ABS AWS A5. 10-92/ER5183
DNV 5183
Si Fe Cu Mn Mg Cr Zn Ti AI
0.4 0.4 0.1 0.5-1.0 4.3-5.2 0.05-0.25 0.25 0.15 Bal

Gas Type Ar
Elongation 17%
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
1.2 6kg spool M518312S

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CONTENTS
SUMMARY
Aluminium - 5% Magnesium Alloy, Metal Inert Gas
(MIG) Welding Wire
Double Shaved and Precision Layer Wound for
Superb Feedability
For Welding Cast and Wrought Aluminium Alloys
Containing Magnesium

CLASSIFICATION
AS/NZS ISO 18273 - S AI 5356
AWS A5.10: ER5356

Austmig 5356 is a precision layer wound Aluminium - 5%
Magnesium wire suitable for a wide range of gas metal arc
welding applications on wrought or cast aluminium alloys
containing magnesium as a major alloying element. Some
grades of wrought aluminium - magnesium alloys which can
be welded with Austmig 5356 are, 5083, 5086, 5454 and 5456.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
0.9 80-190 16-22
1.0 100-230 18-22
1.2 150-250 20-27
1.6 200-330 23-30
AUSTMIG 5356
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CONTENTS
SHIPPING APPROVALS
LR WC/I-1,S; ABS AWS A5. 10-92/ER 5356; DNV 5356
Zn Mg Mn Cr Si Fe Ti AI
0.1 5.2 0.15 0.1 0.25 0.4 0.15 Bal

Gas Type Ar
Elongation 17%
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
0.9
2kg spool
6kg spool
M5356092KG
M535609S
1.0
2kg spool
6kg spool
M5356102KG
M535610S
1.2
2kg spool
6kg spool
M5356122KG
M535612S

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CONTENTS
SUMMARY
Gas Shielded, Metal-Cored Wire
Slag-Free Weld Bead
Higher Deposition Rates
Low Spatter/Smooth Appearance
Better Fusion Profle

CLASSIFICATION
AS/NZS ISO 17632-B - T 492T15 0MA-UH5
AWS A5.18: E70C-6M

Austfl 70C-6M is a metal-cored wire designed for high speed
fllet and butt welding in the downhand position using Argon
+ 18-25% CO
shielding gas mixture. Weld beads are almost

completely slag free with only minimal silicon islands, reducing
the time and effort spent between runs and on cleanup prior to
surface fnishing.
Austfl 70C-6M is recommended for single and multi pass
welding in both fat and horizontal positions for mild steel,
carbon and maganese carbon steels with minimum clean up
and where high deposition rates and effciencies are required
in high productivity, semi automatic and fully automatic welding
installations. Suitable applications include mining buckets,
structural fabrication and tank construction where high speed
welding is required.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 200-350 29-35
1.6 300-450 27-34
*Voltage is determined by arc current and wire arc length.
AUSTFIL 70C-6M
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CONTENTS
SHIPPING APPROVALS
LR 3S, 3YS
C Mn Si S P Cu Fe
0.038 1.46 0.68 0.009 0.012 0.02 Bal

Gas Type Ar+25%CO

Elongation 29%
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
1.2 15kg spool 70C6M12S
1.6 15kg spool 70C6M16S
1.2 250kg drum 70C6M12D

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CONTENTS
SUMMARY
All Purpose Rutile Flux Cored Wire
For Both Single or Multiple Pass Welds
All Positional Wire
Formulated Exclusively For CO
Gas

CLASSIFICATION
AS/NZS ISO 17632-B - T492T1-1CA-UH10
AWS A5.20: E71T-1 H8

Austfl 71T is a rutile fux cored wire designed for excellent
performance in all positional fllet and butt-welding applications.
Austfl 71T is formulated exclusively for use with cost effective
CO

shielding gas.
Austfl 71T is recommended for general purpose all positional
welding of mild, carbon and carbon-manganese steels where
excellent weld profle and penetration is required. Suitable for
applications such as storage tanks, structural fabrication, bridge
construction, machinery and earthmoving equipment. Suitable
for AS/NZS 1554.5 of the structural code; Part 5: Welding of
the steel structures subject to high levels of fatigue loading.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 130-230 25-32
1.6 200-350 25-32
Welding parameters shown above are for DC electrode positive
using 100% CO
shielding gas at a fow rate of 15-20 litres/minute.

AUSTFIL 71T
47
CONTENTS
SHIPPING APPROVALS
LR 3S, 3YS
C Mn Si S P Fe
0.03 1.28 0.44 0.01 0.013 Bal

Gas Type CO

Elongation 26%
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
1.2 15kg spool 71T112S
1.6 15kg spool 71T116S

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CONTENTS
SUMMARY
Rutile Type Flux Cored Joining Wire, Micro Alloyed
Formulated Exclusively for use with Ar/CO

Shielding Gas Mixtures
Excellent Operator Appeal Smooth Spray Arc Transfer
Versatile all Positional Capabilities
Grade 3 Weld Metal Impact Properties

CLASSIFICATION
AS/NZS ISO 17632-B - T492T1-1MA-UH10
AWS A5.20: E71T-1M

An all positional rutile micro alloyed type fux cored welding
wire specifcally formulated for optimum performance using
Ar/CO
shielding gas mixtures.

The exceptionally smooth arc performance produces a
superb weld for single or multipass welding with low spatter
losses in all positions and applications (except vertical down).
Austfl 71T-1M is recommended for the welding of mild,
carbon and carbon-manganese medium steels where good
impact properties at -20C are required.
This high deposition wire offers excellent operator appeal for
general steel fabrications and constructions such as plate
sections, beams, girders, truck chassis/bodies, shipbuilding,
earth moving equipment, storage tanks, bridge construction etc.
Recommended shielding gases are: Argon + 18-25%CO

AUSTFIL 71T-1M
49
CONTENTS
OPERATIONAL DATA
WIRE
SIZE (mm)
WELD
POSITION
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2
Flat
Flat Fillet
Vertical - up
250-300
230-280
170-220
29-35
28-30
24-28
1.6
Flat
Flat Fillet
Vertical - up
300-350
200-350
200-250
28-34
24-34
26-28
Recommended electrical stick out is 15-20mm.
SHIPPING APPROVALS
LR 3S, 3YS
C Mn Si S P B Fe
0.04 1.20 0.42 0.012 0.013 0.001 Bal

Gas Type Ar+25% CO

Elongation 25%
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PALLET SIZE
(KG)
PART NUMBER
1.2 15kg spool 1080 71T1M12S
1.6 15kg spool 1080 71T1M16S

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CONTENTS
SUMMARY
Low Diffusible Hydrogen
Excellent Toughness at Low Temperatures
Outstanding Weldability
Exceeds 27J CVN @ -40

CLASSIFICATION
AS/NZS ISO 17632-B - T494T1-1MA-UH5
AWS A5.20: E71T-1M, E71T-12MJ H8

A rutile fux cored all position wire designed for welding mild
and carbon steels, especially when good impact toughness
is required at sub zero temperatures. Ideal for single and
multi-pass applications, it delivers outstanding welding
performance and produces high quality X-ray clear weld
deposit with a bead contour that is fat to slightly convex.
It can be used over rust, mill scale and some primers with
no pre-cleaning of the steel necessary. Formula XL-525 has
outstanding mechanical properties that resemble those of
E7018 MMAW (SMAW) electrodes, plus high operator
appeal with low fume levels, low spatter and easy slag removal.
Recommended for ship building, storage vessels, off-shore
structures, earth moving equipment and pipe welding.
HOBART XL-525
51
CONTENTS
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 150-300 24-31
1.6 200-350 24-34
SHIPPING APPROVALS
LR 3S, 3YS; ABS 3SA, 3YSA Impact @ -40C 34 ft, lbs
DNV Y40MS BV 3YM; CWB E491T-12MJ-H4;
C Mn Si Ni Fe
0.04 1.24 0.29 0.37 Bal

Gas Type Ar+20% CO

Elongation 29%
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
1.2 15kg spool S283212-029
1.6 15kg spool S283219-029

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CONTENTS
SUMMARY
Low Diffusible Hydrogen
Exceeds 27J CVN @ -40
Outstanding Weldability in all Positions
Actual Certifcation to AWS A5.01 Lot Class: T3

CLASSIFICATION
AS/NZS ISO 17632-B - T494T1-1CA-UH5
1.2mm, AWS E71T-1C, E71T-12CJ H4
1.6mm, AWS E71T-1C, E71T-12CJ H8

Formulated to provide extremely low hydrogen levels. This
outstanding all positional wire produces a high quality X-ray
clear weld deposit with high impact values at low temperature.
Every batch of the TM-71HYD is actual tested to certify the
quoted mechanical property, and the vacuum sealed packaging
further ensures the product integrity upon delivery.
Applications include ship building and repair, earth moving
equipment, structures, pressure vessel and storage vessels.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 100-350 22-34
1.6 200-350 24-34
TM- 71HYD
53
CONTENTS
SHIPPING APPROVALS
MIL-71T-1-HYD
C Mn Si S P Ni Fe
0.05 1.17 0.25 0.014 0.12 0.5 Bal

Gas Type 100% CO

Elongation 26.6%
137J @ -40C
Aged 48 hours @ 104C
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
1.2 15kg spool S245112-K53
1.6 15kg spool S245019-K53

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2G 3G
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CONTENTS
SUMMARY
Fast-Freezing Slag
Low Spatter
Excellent Arc Characteristics
High Impact Strengths at Low Temperatures

CLASSIFICATION
AS/NZS ISO 17632-B - T555T1-1C/MA-2Ni-UH5
AWS A5.29: E81T1-Ni2C/MJ H8

Offers excellent arc stability and low spatter using either
CO
or Ar/CO

mixtures with up to 80% Argon. These weldability
features, combined with low diffusible hydrogen levels and good
impact values makes the wire a good choice for single and
multiple pass welding in all positions.
Applications include ship building, offshore drilling rigs, HSLA
steels and weathering steels with no colour match requirement..
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 100-350 22.34
TM-811N2
55
CONTENTS
SHIPPING APPROVALS
ABS 3YSA; DNV Y40MS; LR 3Ys
Shielding Gas C Mn Si P S Ni
100% CO
0.04 1.02 0.29 0.010 0.007 2.09

75% Ar/25% CO
0.05 1.26 0.44 0.010 0.007 2.07

Gas Type
100% CO
75% Ar/25% CO
Yield Stress
535 MPa 579 MPa
Tensile Stress
600 MPa 662 MPa
Elongation
27.5% 26%
CVN Impact Values
126J @ -40C
95J @ -51C
104J @ -40C
71J @ -51C
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
1.2 15kg spool S283712-K29

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CONTENTS
SUMMARY
Self Shielded or Gasless Flux Cored Joining Wires
For Fast Downhand Fillet and Butt Welding Applications
Excellent Bead Appearance/Low Spatter Levels
Crack Resistant Weld Deposits/Tolerant to Poor Joint Fit-up

CLASSIFICATION
AS/NZS ISO 17632-B - T49ZT4-0NA-H15
AWS A5.20: E70T-4

Fabshield 4 is an outstanding, high deposition rate, (up to 12.7kg/
hr using 2.4mm size wire) self-shielded or gasless fux cored
wire for downhand single or multi-pass welding applications.
It is specifcally designed to de-sulphurise the weld deposit and
thereby resist cracking. Fabshield 4 is particularly suited to the
fast fllet welding of mild and medium strength steels.
Typical applications include the welding of structural members
and machinery. Due to its self shielding arc, Fabshield 4 is ideal
for on site feld construction and repair applications.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
2.4 250-500 28-34
3.0 450-680 28-37
Welding Current DC -
FABSHIELD 4
57
CONTENTS
C Mn Si P S AI Fe
0.27 0.73 0.30 0.11 0.005 1.42 Bal

Elongation 25%
CVN Impact Values Not Required
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
2.4 22.7kg spool S224529-014
3.0 22.7kg spool S224541-014

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CONTENTS
SUMMARY
All Positional Welding Capabilities
Suitable for Single-Pass Applications only
Ideal for Mild and Galvanized Steels

CLASSIFICATION
AS/NZS ISO 17632-B - T49ZTG-1SNA
AWS A5.20: E70T-GS

Fabshield 23 is a general-purpose self-shielded tubular wire
that is designed for welding thin gauge mild or galvanized steel.
Suitable for single-pass applications, especially for fllet lap
welds, you will get outstanding welding performance as
Fabshield 23 produces a smooth spray arc type of transfer
with goods wetting action.
Great for welding outdoors in draughty conditions, this
all-positional wire also provides very low splatter levels,
resulting in a weld bead that is excellent in appearance.
Perfect for on site applications such as welding mild steel/
galvanized gates, fences, frames, sheds, prefab building
fabrications, ornamental ironwork, general fabrication, etc.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
TYPICAL
STICKOUT
(mm)
0.8 25-125 14-16 12
0.9 55-120 17-20 12
FABSHIELD 23
59
CONTENTS
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C Mn Si S P AI Fe
0.18 0.65 0.40 0.01 0.01 1.30 Bal

NOTE: Yield Stress and impact values not applicable.
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
0.8 4.5kg spool S222306-022
0.9 4.5kg spool S222308-022
0.9 15kg spool S222308-029

1G
2G 3G
4G
1F
2F
4F
60
CONTENTS
SUMMARY
All Positional Welding Capabilities
Suitable For Single Pass/Multi-pass Applications
Suitable for Mild/Galvanised Steels

CLASSIFICATION
AS/NZS ISO 17632-B - T49ZT11-1NA-H15
AWS A5.20: E71T-11

Fabshield 21B is a general purpose self-shielded tubular wire
that is designed for single and multi-pass welding of thin gauge
to 20mm thick mild or galvanized steels. Great for welding fllet or
lap welds, you will fnd that this all-position wire has high operator
appeal, producing a smooth spray-like transfer with low spatter
levels, excellent weld appearance and easy to remove slag.
Perfect for on-site applications such as the welding of machine
parts, galvanized steels tanks, gates, frames, sheds, prefab
construction, light structures, general fabrication etc.
OPERATIONAL DATA
Welding parameters shown below are for
DC Electrode negative only.
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
TYPICAL
STICKOUT
(mm)
0.9 55-120 17-20 12
1.2 130-160 15-18 12
1.6 150-250 18-20 19
2.0 200-300 16-23 19
FABSHIELD 21B
61
CONTENTS
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C Mn Si S P AI Fe
0.28 0.34 0.15 0.008 0.003 1.04 Bal

Elongation 22%
CVN Impact Values Not Required
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
0.9 4.5kg spool S222108-022
1.2 4.5kg spool S222112-022
1.2 15kg spool S222112-029
1.6 15kg spool S222119-029
2.0 15kg spool S222125-029

1G
2G 3G
4G
1F
2F
62
CONTENTS
SUMMARY
Welds Out of Position at High Currents
Low Hydrogen Weld Deposit
Excellent Slag Removal
No Shielding Gas Required
High Impact Strength at Low Temperatures
Excellent Mechanical Properties Under a
Wide Range of Heat Input

CLASSIFICATION
AS/NZS ISO 17632-B - T494T8-1NP-H10
AWS A5.20: E71T-8JD H8

Low hydrogen T-8 self-shielded, all positional fux cored wire,
producing a stable arc and fat bead profle, especially suited
for vertical-up welds at high currents with excellent mechanical
properties and a tensile strength of 490 MPa. Capable of
depositing X-ray quality welds, making it highly suitable for critical
welding applications requiring a high degree of crack resistance
due to its low diffusible hydrogen levels, less than 6.7ml per
100g of weld metal deposited. XLR-8 has been designed for
single and multi-pass welding applications with improved
productivity in out-of-position welding, offering high impact
strength of (42J) at sub zero temperatures to -40C.
Specifcally designed for increased productivity and high
deposition rates on challenging structural steel erection, heavy
equipment repair, mining equipment, bucket repairs, storage
tanks, pipe spooling, ship construction and site work applications.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.6 180-300 18-25
1.8 170-330 18-25
2.0 200-360 18-26
Recommended electrical stick out is 25-35mm. Welding Current DC -
HOBART XLR-8
63
CONTENTS
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SHIPPING APPROVALS
ABS 3YSA; AWS D1.8 Conformance
C Mn Si P S AI Fe
0.19 0.51 0.17 0.009 0.006 1.51 Bal

Yield Stress
470 MPa
Tensile Stress
580 MPa
Elongation
25%
CVN Impact Values
42J @ -40C
Diffusible Hydrogen
6.7ml/100g of weld deposited
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
1.6 15kg spool S225719-053
1.8 15kg spool S225724-053
2.0 15kg spool S225725-053
2.0 22.7kg coil S225725-014

1G
2G 3G
4G
1F
2F
4F
64
65
HARDFACING ELECTRODES
Abrasocord 43 ........................................................ 66-67
Abrasocord 350....................................................... 68-69
Abrasocord 700....................................................... 70-71
Tubecord D - 2355 .................................................. 72-73
Tubecord E - 2460 .................................................. 74-75
HARDFACING SOLID MIG WIRES
Austmig TD-600 ..................................................... 76-77
HARDFACING SELF SHIELDED FLUX CORED WIRES
Mckay Tube-Alloy 240-0.......................................... 78-79
Mckay Tube-Alloy 258-0.......................................... 80-81
Mckay Tube-Alloy A43-0 ......................................... 82-83
HARDFACING GAS SHIELDED FLUX CORED WIRES
Mckay Vertiwear-600 .............................................. 84-85
HARDFACING PRODUCTS
CONTENTS
CONTENTS
66
CONTENTS
SUMMARY
Tough, Wear Resistant Complex Carbide Type Deposit
For Hard Surfacing Components Subjected to Extreme
Abrasion and Moderate to Heavy Impact
Similar Deposit Type to Tubecord E-2460

IDENTIFICATION
Coating - Black Tip - Plain Imprint - WIA AC 43

CLASSIFICATION
AS/NZS 2576: 2465-A4


Abrasocord 43 is a heavy coated, hard surfacing electrode
depositing extremely hard, abrasion resistant Chromium/
Niobium carbides in an austenitic matrix. It is ideal for hard
surfacing applications where resistance to extreme abrasion
(in particular sliding abrasion) and moderate to heavy impact
are required. Due to the nodular shape of the complex
carbides, Abrasocord 43 deposits are capable of withstanding
heavier impact levels than standard chromium carbide grades.
Typical applications include bucket teeth/lips, grizzlies, press
screws, crusher hammers and ripper teeth to name but a few.
Abrasocord 43 deposits are non-machineable, grindable, prone
to fne relief checking and should be restricted to 3 layers high.
While two layers of Abrasocord 43 may be required for maximum
wear resistance, this complex carbide alloy has lower dilution
sensitivity than straight chromium carbide deposits.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
3.2 380 115-140 19
4.0 380 140-185 22
5.0 450 190-255 24
ABRASOCORD 43
67
CONTENTS
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C Mn Cr Nb Fe
5.0 0.7 22.0 7.0 Bal

Single Layer onto Mild Steel Typical Hardness 60-65 HRc
Multi-Layer Typical Hardness 64-69 HRc
Single layer deposit hardness may vary depending
on base metal type and degree of dilution
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
3.2 5 15 16 AC4332
4.0 5 15 11 AC4340
5.0 5 15 6 AC4350

1G
2G
68
CONTENTS
SUMMARY
Tough, Machineable, Wear Resistant Martensitic Steel Deposit
For Hard Surfacing Steels Subjected to Metal-to-Metal Wear
Under Compressive Loading

IDENTIFICATION
Coating - Brown Tip - Yellow Imprint - WIA AC 350

CLASSIFICATION
AS/NZS 2576: 1435-A4


Abrasocord 350 is a smooth running, AC/DC electrode which
deposits a tough wear resistant low carbon martensitic steel
alloy. It is suitable for the heavy build-up and surfacing of steel
components subjected to metal-to-metal wear and compressive
loading such as, track components, gears and shafts, etc.
Abrasocord 350 deposits an air hardening C-Mn-Cr steel alloy
which is machineable and can be readily hot forged. It offers
high compressive strength and excellent resistance to impact
for all types of metal-to-metal wear.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
3.2 380 100-140 19
4.0 380 150-200 22
5.0 450 190-240 24
ABRASOCORD 350
69
CONTENTS
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C Mn Si Cr Fe
0.2 0.4 0.3 2.8 Bal

PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
3.2 5 15 24 HF35032
4.0 5 15 16 HF35040
5.0 5 15 9 HF35050

1G
2G
70
CONTENTS
SUMMARY
Wear Resistant, High Carbon Martensitic Steel Deposit
For a Wide Range of General Hard Surfacing Applications,
Such as Points, Tynes, Lips, Blades and Augers, ect.

IDENTIFICATION
Coating - Grey Tip - Orange Imprint - WIA AC 700

CLASSIFICATION
AS/NZS 2576: 1855-A4


Abrasocord 700 is a smooth running, AC/DC electrode
which deposits an air hardening martensitic Cr-Mo-V steel
alloy. Abrasocord 700 deposits one of the hardest steel alloys
available and is free from relief checks. Applications include
the surfacing of post hole augers, agricultural points, shares
and tynes, grader and cultivator blades and other components
subject to fatigue or fexing during service.
Abrasocord 700 deposits an air hardening steel alloy which
can be readily hot forged and offers good resistance to all
types of abrasion under low to moderate impact conditions.
In the as welded condition Abrasocord 700 weld metal
cannot be machined without prior heat treatment.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE *(A)
ARC VOLTAGE
RANGE **(V)
3.2 380 90-130 19
4.0 380 140-180 22
5.0 450 160-240 24
ABRASOCORD 700
71
CONTENTS
C Mn Si Cr Mo V Fe
0.7 0.3 0.5 8.5 0.3 0.5 Bal

PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
APPROX
NO. OF
RODS
PER KG
PART
NUMBER
Packet Carton
3.2 5 15 27 HF70032
4.0 5 15 18 HF70040
5.0 5 15 10 HF70050

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CONTENTS
SUMMARY
High Chrome Carbide
Improved Abrasion Resistance
Welds can be Shaped by Grinding

IDENTIFICATION
Coating - Black Tip - Light Green

CLASSIFICATION
AS/NZS 2576: 2355-A1*
* Nearest Classifcation

DESCRIPTION
Tubecord D - 2355 deposits are high in carbon and chromium
resulting in improved abrasion resistance. Tubecord D - 2355
is ideal for hard surfacing components subjected to heavy
abrasion and moderate impact loading.
No preheat is required for direct application onto grey cast
iron, low carbon or manganese steels.
Applications include the hard surfacing of dredge bucket lips,
shovel buckets, scraper and dozer sides, cone crushers and
mill hammers, etc. Deposits are grindable, subject to relief
checking and may be multi-layered up to 3 layers. Features
include, controlled fume levels, minimal spatter, easy bead
deposition and low penetration.
Tubecord D - 2355 is suitable for AC or DC applications.
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
ELECTRODE
LENGTH (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
6.3 450 85-135 25
TUBECORD D - 2355
73
CONTENTS
C Mn Cr Fe
5.5 1.5 40.0 Bal

Single Layer Typical Hardness 55-60 HRc
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
PART
NUMBER
Packet Carton
6.3 5 15 TUBD60
APPLICATIONS
Dredge Bucket Lips
Shovel Buckets
Cone Crusher

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CONTENTS
SUMMARY
All Tubecord Electrodes are 450mm Long.
6.3mm Tubecord E - 2460 is also Suitable for Vertical Up
and Overhead Welding Positions.
All Tubecore Electrodes are Coated with a Moisture
Resistant, Non Alloying, Black Flux Coating, Resulting
in Infnate Storage life!

IDENTIFICATION
Coating - Black Tip - Blue

CLASSIFICATION
AS/NZS 2576: 2460-A1

DESCRIPTION
Tubecord E - 2460 deposits contain carbon, chromium,
niobium and molybdenum alloys for good resistance to
both impact and abrasion:
Tubecord E - 2460 produces a similar complex carbide
iron deposit to the popular Abrasocord 43 electrode.
No preheat is required for direct application onto grey
cast iron, low carbon or manganese steels.
Applications include the hard surfacing of grizzly bars,
bucket teeth, crusher hammers, rail ballast tampers,
dredger and ripper teeth, etc. Deposits are grindable, subject
to relief checking and should be restricted to 3 layers high.
Features include, controlled fume levels, minimal spatter,
easy bead deposition and low penetration.
Tubecord E - 2460 is suitable for AC or DC applications.
TUBECORD E - 2460
75
CONTENTS
OPERATIONAL DATA
ELECTRODE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
6.3 90-130 25
8.0 135-185 29
**6.3mm only
C Cr Mo Nb V Mn Si Fe
4.0 26.5 0.9 7.9 0.4 0.8 1.5 Bal

Single Layer Typical Hardness 58-61 HRc
PACKAGING DATA
ELECTRODE
SIZE (mm)
PACKAGING
(KG)
PART
NUMBER
Packet Carton
6.3 5 15 TUBE60
8.0 5 15 TUBE80
TYPICAL APPLICATIONS
Grily Bars
Bucket Teeth
Crusher Hammers

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** **
76
CONTENTS
SUMMARY

Copper Coated, Chromium Alloy Gas Metal Arc
(MIG) Welding Wire
For Hard Surfacing Components Subjected
to Severe Abrasion and Heavy Impact

CLASSIFICATION
AS/NZS 2576: 1855-B6

DESCRIPTION
Austmig TD - 600 is a copper coated, chromium alloy welding wire
depositing weld metal with a hardness of 55-60 HRc which
has a high resistance against severe abrasion and impact.
The deposit is non-machineable but can be shaped by grinding
Typical applications include: excavator blades, bucket lips,
bucket teeth, screw conveyors, crushing mills, shear blades.
OPERATIONAL DATA
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 120-340 18-32
AUSTMIG TD - 600
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CONTENTS
C Si Mn P S Cr Fe
0.45 3.00 0.40 0.025 0.020 9.00 Bal

As Welded - Two Layers 55-60 HRc
Recommended Shielding Gases:
Argon/18 - 25% CO
, Ar/CO
or 100% CO
APPLICATIONS

Excavator Blades Bucket Teeth
Screw Conveyors Crushing Mills
Sheer Blades
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
AND TYPE
PART NUMBER
1.2 15kg MTD60012S

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CONTENTS
SUMMARY
Self Shielded Hard Surfacing Flux Cored Wire
General Purpose Alloy with Good Abrasion
and Impact Resistance
Chromium Carbide - Alloy Steel
Non Machinable, Diffcult to Grind

CLASSIFICATION
AS/NZS 2576: 2155-B7

DESCRIPTION
McKAY Tube-Alloy 240-O is a self shielded, fux cored hard
surfacing wire that deposits a chromium carbide alloy steel.
It is an excellent general purpose alloy due to a combination
of good abrasion and impact resistance.
McKAY Tube-Alloy 240-O is designed for overlaying carbon,
low alloy or austenitic manganese base metals. The smooth
globular type arc transfer gives minimal spatter and the
minimum slag cover allows the wire to operate well without
de-slagging between weld passes in automatic applications.
Some relief check cracking will occur however it is not
detrimental to the wear properties of the deposit and
provides some degree of stress relief for the weld metal.
OPERATIONAL DATA
The recommended operating parameters are for DC positive
with an electrode stick out of 16-25mm for the 1.2mm size,
25-35mm for 1.6mm. Out-of-position welding is limited to a
horizontal shelf technique.
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 120-275 19-27
1.6 275-400 24-29
McKAY TUBE-ALLOY 240-O
79
CONTENTS
C Mn Si Cr Fe
3.20 1.80 1.90 15.50 Bal

TYPICAL MECHANICAL PROPERTIES (AS WELDED):
Number of
Layers
As-deposited on
1020 Steel Mn Steel
Hardness
1 40 Rc 35 Rc
2 48 Rc 42 Rc
3-5 52 Rc 50 Rc
Abrasion Resistance: Very Good
Impact Resistance: Fair
Non-Machinable: Grinding is diffcult
Cannot be Flame Cut
Deposit will Relief check Cracks
Thickness should be Limited to Five Layers Maximum
APPLICATIONS
Ammonia Knives Hammer Mill Hammers
Augers Impactor Crusher Bars
Bucket Teeth and Lips Manganese Pump Shells
Bulldozer End Bits & Blades Mill Guides
Conveyer Screws Muller Tires
Crusher Jaws and Cones Pipeline Ball Joints
Crusher Rolls Pulverizer Hammers
Cultivator Chisels & Sweeps Scraper Blades
Dragline Buckets Screw Conveyors
Sheepsfoot Tampers Sizing Screens
Dredge Pump Impellers
and Side Plates
PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
(KG)
PART NUMBER
1.2 11.3 S604012-029
1.6 11.3 S604019-029

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CONTENTS
SUMMARY
Self Shielded or Open Arc Hard Surfacing Flux Cored Wire
Hard Wearing Martensitic Steel Alloy Deposit
Tough, Hard Tool Steel Weld Metal Composition
Good Impact and Abrasion Resistance
Excellent Resistance to Metal-to-Metal Wear
Weld Deposits Grindable Only

CLASSIFICATION
AS/NZS 2576: 1550-B7*
*Nearest Classifcation

DESCRIPTION
McKAY Tubealloy 258-O is a fabricated type, open arc tubular
fux cored wire depositing a Cr-Mo-W Martensitic steel alloy.
It is designed for surfacing mild and low alloy steel components
subject to moderate abrasive wear and impact under high
compressive stresses and/or at temperatures up to 530C.
Crack free deposits can be obtained by controlled heat input
or the use of preheat.
OPERATIONAL DATA
Welding parameters shown below are for DC electrode positive.
An electrode stick out length of 12-25mm is recommended for
1.2mm size, 25-35mm for 1.6mm.
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 120-230 24-27
1.6 225-350 30-34*
McKAY TUBE-ALLOY 258-O
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CONTENTS
C Mn Si Cr Mo W Fe
0.45 1.40 0.80 6.00 1.50 1.50 Bal

Number of
Layers
As-deposited on
1020 Steel Mn Steel
Hardness
1 49 Rc 51 Rc
2 53 Rc 54 Rc
3 57 Rc 57 Rc
Abrasion Resistance: Good
Impact Resistance: Good
Non-Machinable: Grinding only
Flame Cutting: Diffcult
Deposit will Relief Check Cracks
APPLICATIONS
Coupling Boxes Dragline Chains
Kiln Trunnions Mill Guides
Spindles Wobbler Ends

PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
(KG)
PART NUMBER
1.2 11.3 S605812-029
1.6 11.3 S605819-029

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CONTENTS
SUMMARY
Self Shielded or Open Arc Hard Surfacing
Flux Cored Wire
Niobium-Chromium Carbide Iron Weld Deposit
Resistant to Severe High and Low Stress Abrasion
Low to Moderate Impact Loading
Weld deposits are to be Shaped by Grinding Only

CLASSIFICATION
AS/NZS 2576: 2460-B7

DESCRIPTION
McKAY Tube-Alloy A43-O is a fabricated type, self shielding
tubular fux cored wire depositing a high chromium-niobium
surfacing alloy which resists severe high and low stress abrasion
and low to moderate impact.
The weld deposit will check crack readily and out performs
straight C-Cr hard surfacing alloys. It can also be used where
high temperature (650C) wear resistance is required. Spatter
level is low, slag cover is minimal and is easily removed.
OPERATIONAL DATA
The recommended operating parameters are for DC positive
with an electrode stick out length of 20-35mm.
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.6 300-350 30-34
Other wire sizes and spool weights are available on indent only.
McKAY TUBE-ALLOY A43-O
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CONTENTS
C Mn Si Cr Nb Fe
5.50 0.20 1.0 22.00 6.50 Bal

Number of
Layers
As-deposited on
1020 Steel Mn Steel
Hardness
1 56-60 Rc 45-50 Rc
2-3 60-64 Rc 54-58 Rc
Abrasion Resistance: Excellent
Impact Resistance: Poor
Non-Machinable: Grinding only
Deposit will Relief Check Cracks
APPLICATIONS
Augers Bucket Lips and Teeth
Coal Feeder Screws Coal Pulverizer Rolls & Tables
Coke Chutes Coke Pusher Shoes
Conveyer Screws Fan Blades
Grizzly Bars and Fingers Pipeline Ball Joints
Muller Tires Paving Agitator Screws
Pipeline Ball Joints Pub Mill Paddles
Scraper Blades Sheepsfoot Tampers
Sizing Screws
Dredge Cutter Heads & Teeth
Dredge Pump Inlet Nozzle
and Side Plates

PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
(KG)
PART NUMBER
1.6 11.3 S607719-029

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CONTENTS
SUMMARY
Suites Out-of Position Applications
Multi-Purpose Martensitic Steel
Moderate Abrasive Wear and Medium to High Impact
Weld Deposits - Machineable

CLASSIFICATION
AS/NZS 2576: 1855-B5*
*Nearest Classifcation

DESCRIPTION
McKAY Vertiwear 600 is a gas shielded, all position, hard
surfacing fuxcored wire designed to operate in a smooth
semi-spray arc transfer. The weld metal control is superior to
competitive gas shielded hard surfacing wires allowing higher
deposition and greater productivity in out-of-position applications.
Excellent operator appeal in all positions.
McKAY Vertiwear 600 deposits a multi-purpose martensitic steel
alloy and can be used to hard surface mild and low alloy steel
components subject to moderate abrasion coupled with medium
to high impact. It also exhibits excellent compressive strength
and metal-to-metal wear resistance.
The recommended shielding gas for Vertiwear 600 is
75% Argon - 25% CO
.
OPERATIONAL DATA
The recommended operating parameters are for DC positive with
an electrode stick out length of 20-35mm.
WIRE
SIZE (mm)
WELDING CURRENT
RANGE (A)
ARC VOLTAGE
RANGE *(V)
1.2 165-185 24-28
McKAY VERTIWEAR-600
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CONTENTS
C Mn Si Cr Mo Fe
0.40 0.75 0.60 6.50 1.00 Bal

TYPICAL MECHANICAL PROPERTIES (AS WELDED)
Number of
Layers
As-deposited
on
1020 Steel
Hardness
1 52 Rc
2 56 Rc
3-8 57 Rc
Hardness as-
deposited
Time at Temp
Hardness after Tempering
535C 620C
55 10 Hours 54 46
20 Hours 49 40
80 Hours 47 40
Abrasion Resistance: Good
Impact Resistance: Good
Machinability Good
Magnetic
APPLICATIONS
Coupling Boxes Dragline Chain
Dredge Ladder Rolls Kiln Trunnions
Mill Guides Sliding Metal Parts
Wobber Ends

PACKAGING DATA
WIRE
SIZE (mm)
PACK SIZE
(KG)
PART NUMBER
1.2 15 S607112-029

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4G
The following pages cover a range of technical
information and data tables pertaining to the feld of
welded fabrication and general engineering.
This section is designed to provide a ready reference
guide for welding engineers, design costing personnel,
workshop supervisors and welding operators, and to
foster higher quality, higher productivity welding.
GLOSSARY .......................................................... 88-105
OXY-ACETYLENE FLAME ADJUSTMENT .........106-107
WELDING SYMBOLS .........................................108-115
ELECTRODE CLASSIFICATIONS
Manual Metal Arc Welding Electrodes ....................116-123
Gas Metal Arc Welding Ferritic Steel Electrodes ...... 124-126
Flux Cored Arc Welding Electrodes ....................... 127-129
Manual Metal Arc and Gas Metal Arc Welding
for Aluminium and Stainless Steel Electrodes .......... 130-131
Repair and Hardfacing .......................................... 132-133
Submerged Arc Welding Electrodes and Fluxes ... 134-135
WELD DEPOSITION AND COSTING DATA
Users Guide........................................................... 136-147
Mass of Weld Metal in Joint ................................... 148-153
Quantity of Consumables Required....................... 154-157
Deposition Rates ................................................... 158-165
Duty Cycles ........................................................... 166-167
Electrode Consumption for Typical Butt Joints ...... 168-169
CONTENTS
TECHNICAL INFORMATION
CONTENTS
87
WELDABILITY GUIDE FOR STEELS .................170-193
COMMON WELD TROUBLES ...........................194-199
SI UNITS AND CONVERSION DATA ..................200-203
Table 1.
Conversion from Inches to Millimetres ..........................204
Table 2.
Travel and Wire Feed Speeds .......................................205
Table 3
C - F Temperature Conversions.......................... 206-209
Table 4.
Comparison of Hardness Scales ...................................210
Table 5.
Stress and Energy Conversions .................................... 211
Table 6.
Wire and Sheet Sizes ............................................ 212-213
SYMBOLS FOR ELEMENTS AND
GEOMETRIC FORMULAE ........................................ 214
CONTENTS
TECHNICAL INFORMATION TECHNICAL INFORMATION
CONTENTS
88
CONTENTS
The following is a selection of some of the more common welding
terms and abbreviations in current Australian usage. Please refer
to Australian Standard AS2812 (Welding, Brazing and Cutting of
Metals - Glossary of Terms) for a more comprehensive list.
AMPERAGE - The measurement of the amount of electricity
fowing past a given point in a conductor per second.
Current is another name for amperage.
ANGLE OF BEVEL - The angle at which the edge of a joint is
prepared for making a weld, refer to FIG 1. (A) - (F) for typical
examples
ARC BLOW - An uncontrolled defection of a welding arc caused
by an uneven distribution of magnetic feld around the arc.
ARC LENGTH - The distance from the end of the electrode
to the parent material.
ARC VOLTAGE - The voltage across the welding arc.
ARC WELDING (AW) - Fusion welding in which heat for
welding is obtained from an electric arc or arcs.
ARC WELDING GUN - A device used in semi-automatic and
automatic arc welding to transfer current, guide the consumable
electrode and direct shielding gas when used.
AS-WELDED - The condition of weld metal, welded joints or
weldments after welding prior to any subsequent thermal or
mechanical treatment.
BACKING - A weld backing maybe incorporated in welded joint
design to simplify the root pass. Backing of suitable material
can be incorporated in the weldment, or alternativley removable
temporary backing material can be used. e.g. ceramic tiles
BACK-STEP WELDING - A welding technique wherein the
increments of weld metal are deposited in a direction opposite to
that of progression.
BARE ELECTRODE - A fller metal electrode consisting of a
single metal or alloy that has been produced into a wire, strip or
bar form which has no fux coating or covering applied to it.
GLOSSARY
89
CONTENTS
BASE (PARENT) METAL - The metal to be welded or joined other
than the fller metal.
BASIC ELECTRODE - A fux coated electrode in which the
covering contains a high proportion of basic materials, such as
limestone and furospar etc.
BRAZE WELDING (BW) - The joining of metals using similar joint
designs as for fusion welding. However, the parent metal is not
melted as in fusion welding. A non-ferrous alloy with a melting
point above approx. 500C and below that of the parent metal is
normally used as the fller metal and is deposited without the aid
of capillary action, as in brazing.
BRAZING - A joining process in which, during heating, molten
fller metal is made to fow by capillary action between a narrow
joint preparation. In general, the melting point of the fller metal is
above approx. 450C, but is always below the melting temperature
of the parent metal. A fuxing agent is usually used to promote the
fow of fller metal along and around the joint.
BRONZE WELDING - Term used to describe Braze Welding using
a Copper rich fller metal.
BUTTERING - A material preparation process in which one or
two layers of weld metal are deposited on the surfaces to be
joined. The buttering provides a suitable transition weld deposit for
subsequent completion of the joint.
BUTT WELD - A weld in which the weld lies substantially within
the extension of the planes of the surfaces of one or more of the
pads joined, see Fig 1 for typical examples.
CDT - Controlled Droplet Transfer
CELLULOSE ELECTRODE - A fux coated electrode in which
the covering contains at least 15 percent cellulose and up to 30
percent titania as rutile or titanium white.
CO
WELDING - Gas Metal-Arc welding using CO
as the
shielding gas, see preferred term - Gas Metal Arc Welding.
CONSTANT VOLTAGE POWER SOURCE - An arc welding power
source whose terminal voltage remains substantially constant
between full load and no load conditions.
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CONSUMABLES - Materials directly consumed in the making
of a weld, including electrodes, fux heating and shielding gas
and fller wire etc.
CORED ELECTRODE - A consumable electrode having a
core of fux and/or alloying ingredients.
COVERED ELECTRODE - A fller metal electrode, used in
arc welding, consisting of a metal core wire with a relatively
thick covering of fux which provides protection for the molten
metal from the atmosphere, improves the properties of the
weld metal and stabilises the arc.
CRATER - A depression left in the weld where the arc is broken.
CONSUMABLE GUIDE WELDING - see Electroslag Welding.
DEFECT - One or more discontinuities that cause non
compliance of a weld.
DEPTH OF FUSION - The distance from the fusion face
to that point within the joint at which fusion ceases, see
Fig 2.(a) and (b).
DEPOSITION EFFICIENCY -
(a) For manual metal arc welding electrodes, the ratio of the
mass of deposited metal to the mass of the core wire consumed
(excluding stubs); expressed as a percentage.
(b) For continuous electrodes, the ratio of the mass of
deposited metal to the mass of electrode consumed; expressed
as a percentage. For 85% deposition effciency means 85kg
of weld metal was produced from 100kg of electrode metal.
DEPOSITION RATE - The mass of metal deposited
(excluding spatter) in a unit of time.
DILUTION - The alteration of composition of the weld metal
deposited from a fller metal or electrode due to mixing with
the melted parent metal. It is expressed as a percentage of
melted parent metal to the weld metal.
DIP TRANSFER - see Short Circuiting Arc Transfer.
DISCOUNTINUITY - a faw in the weld which complies or may
comply with the acceptance standard
GLOSSARY
91
CONTENTS
DROOPING CHARACTERISTIC POWER SOURCE - An arc
welding power source whose terminal voltage drops to a value
appreciably below the open circuit voltage (O.C.V.) after the
arc has been initiated.
DUTY CYCLE - (a) Power Source Duty Cycle is the amount
of time a welding machine can be used at a given amperage,
generally expressed as a percentage of a 5 min. period, eg.
60% at 300amps means the machine can be used at 300
amps for 3 mins in every 5 mins
(b) Operator Duty Cycle is the ratio of welding or cutting time
to the total work time expressed as a percentage.
ELECTRODE - A component of the welding circuit through
which current is immediately conducted to the arc, molten
slag, or base metal.
(a) Non-consumable electrode - an electrode which does
not provide metal eg. a Tungsten electrode.
(b) Consumable electrode - an electrode which provides
fller metal.
ELECTRODE NEGATIVE - Arc welding using direct current
in which the electrode is connected to the negative pole of the
welding power source. Also referred to as, straight polarity.
ELECTRODE POSITIVE - Arc welding using direct current
in which the electrode is connected to the positive pole of the
welding power source. Also referred to as, reverse polarity.
ELECTRODE STICKOUT - In automatic and semi-automatic
arc welding, the length of the electrode projecting beyond the
region of current pick-up / contact tip during welding.
ELECTROSLAG WELDING (ESW) - A continuous wire
electrode, vertical fusion welding process in which the molten
pool of metal and covering slag are confned to the joint by
copper shoes. The wire feeding nozzle progresses automatically
up the joint or in the case of the consumable guide variant, is
melted as the weld level rises. The heat for fusion is generated
by the electrical resistance of the slag bath.
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FILLET WELD - A weld or series of welds of approximately
triangular cross-section joining two surfaces approximately
at right angles to each other in a lap joint, tee joint or corner
joint. Note. The bulk of the weld metal is outside the planes
made by the surfaces of the base metals, see Fig 2, (b)
and (d) for typical examples.
FLAT POSITION - The position in which welding is
performed from the upper side of the joint and the weld
face is approximately horizontal (Sometimes called downhand
welding), see Fig 3, 1F and 1G positions.
FLUID SLAG - A slag which fows freely during whilst molten
during welding.
FLUX - A substantially non-metallic material used during welding,
brazing, braze welding or soldering to clean the surfaces of the
joint chemically, to prevent atmospheric oxidation and to reduce
impurities or foat them to the surface in the form of a slag.
FRIABLE SLAG - A slag that crumbles easily to aid removal.
FUSION FACE - The portion of a surface, or an edge, which is to
be fused (melted) in making a fusion weld, see Fig 2(a) and (b).
FUSION ZONE - The area of parent metal melted as determined
on the cross section of a weld, see Fig 2(a) and (b).
FLUX CORED ARC WELDING (FCAW) - Arc welding using
a continuous, consumable, fux cored wire (electrode) which
provides the fller metal. Gas shielding, alloying addlions and
slag coverage may be provided by the fux contained within the
electrode. Gas shielding may or may not be required.
FUSION WELDING - Welding in which similar parent metals are
fused (melted) together with or without the use of a fller metal of
similar composition.
GAS METAL ARC WELDING (GMAW) - The preferred
terminology for the process of arc welding using a continuous,
consumable, solid wire (electrode) which provides the fller metal
and in which shielding is obtained entirely from an externally
supplied gas or gas mixture. The process is similar to and also
known as MIG, MAG AND CO

welding.
GLOSSARY
93
CONTENTS
GAS PORE - A weld cavity caused by entrapped gas.
GAS TUNGSTEN ARC WELDING (GTAW) - The preferred
terminology for the process of arc welding, with or without added
fller metal, using a non-consumable electrode of pure or activated
tungsten, shielded by an externally supplied gas or gas mixture.
The process is similar to and also known as TIG, Heliarc or
Argonarc welding.
GAS WELDING - Welding in which the heat for welding is
produced by the combustion of a gas mixture. Filler metal may or
may not be used. The most popular gas combination is oxygen
/ acetylene however oxygen / LP gas, air / acetylene or air / LP
gas are mixtures which may be used, depending on the joining
process adopted.
GLOBULAR TRANSFER - Metal transfer which takes place
as globules of diameter substantially larger than that of the
consumable electrode from which they are transferred.
HARD SURFACING - Surfacing with a wear resistant material.
The preferred term to hardfacing.
HEAT AFFECTED ZONE (HAZ) - The portion of parent
metal which has not been fused but has nevertheless been
metallurgically affected by the heat of welding, brazing or cutting,
Refer to Fig 2(a) and (b) for clarifcation.
HERTZ - Hertz is often referred to as cycles per second.
In Australia, the frequency or directional change of alternating
current is usually 50 hertz.
HIGH FREQUENCY - Covers the entire frequency
spectrum above 50,000 Hz. Used in GTA welding for arc
ignition and stabilization.
HORIZONTAL POSITION - The position of welding wherein
the line of the weld root is approximately horizontal, see Fig 3,
2F and 2G positions.
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HYDROGEN CONTROLLED ELECTRODE - An electrode
depositing weld metal containing not more than a specifed
quantify of diffusible hydrogen in the deposited weld metal
when assessed in accordance with the appropriate standard.
The category of such electrodes may be sub-divided into
classifcations of medium hydrogen, low hydrogen and very low
hydrogen, each having successively lower allowable levels of
diffusible hydrogen.
INCLUDED ANGLE - The angle between the planes of the fusion
faces of the parts to be welded, see Fig 1 for typical examples.
INDUCTANCE - Inductance comes from an inductor (stabilizer).
The inductor slows down the changes in current, changing
the machines rate of response and number of short circuits
per second. An inductor helps limit the amount of spatter, and
generally improves the wetting out of the weld puddle.
INTERMITTENT WELD - A series of welds at specifed intervals
along a joint, see Fig 7 (c).
INTERRUN TEMPERATURE - In a multi run weld, the
temperature of the weld and adjacent parent metal immediately
prior to the deposition of the next weld run.
Also called INTERPASS TEMPERATURE.
INVERTER - Power source which increases the frequency of the
incoming primary power, thus providing for a smaller size machine
and improved electrical characteristics for welding,
such as faster response time and more control for pulse welding.
IRON POWDER ELECTRODE - A fux coated electrode in which
the covering contains a high percentage of iron in the form of
powder to improve deposition effciency typically 110-130%.
JOINT PENETRATION - The minimum depth of fusion into
a joint, excluding reinforcement.
JOINT PREPARATION - Details of the edge preparations
and set up of workpieces for welding.
Refer to Fig 1, (A)-(F) for examples.
Ksi - (kips) kilo (1000) pounds per square inch.
GLOSSARY
95
CONTENTS
LAND - The straight portion of a fusion face between the edge
of the root face and: (a) the sloping face of a bevel preparation,
or (b) the curved part of a J edge preparation, see Fig 1, (F).
LANDING - See root face
LAP JOINT - A joint between two overlapping members
approximately in the same plane, see Fig 9, (C).
LEG LENGTH - The distance between the root and the toe of a
fllet weld. Leg length is the dimension used to size a fllet weld to
AS1101.3. Leg length is known as the z dimension in ISO 2553,
see Fig 2(d) and weld symbols section.
LOW HYDROGEN ELECTRODE - see Hydrogen
Controlled Electrode.
MAG WELDING - Metal Active Gas, see Gas Metal Arc Welding.
MANUAL METAL ARC WELDING (MMAW) - Arc welding with
a fux covered electrode manually applied by the welder without
automatic or semi-automatic replacement of the electrode.
Shielding is provided only by decomposition of the electrode
covering. In American terminology, known as, Shielded Metal
Arc Welding (SMAW).
MECHANISED WELDING - Welding with equipment which
performs the welding operation under preset conditions under
the constant control of a welding operator.
MIG WELDING - Metal Inert Gas, see Gas Metal Arc Welding.
MITRE FILLET WELD - A fllet weld of equal leg lengths in which
the face of the weld is essentially fat.
MULTIPLE ARC WELDING - Welding wherein a single
process runs with more than one electrode from a single
power source eg. twin arc, or a single process operates with
more than one electrode from separate power sources and
separate nozzles eg. tandem arc. Essentially a single weld
pool is maintained throughout.
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CONTENTS
NARROW GAP WELDING - A modifcation of conventional
automatic arc Welding of thick sections where square
preparations or V preparations with small included angles
and narrow gaps are used.
NON-TRANSFERRED ARC - A plasma arc struck between the
tungsten electrode and the torch nozzle.
OPEN-CIRCUIT VOLTAGE (OCV) - The voltage between
the live output terminals of a welding power source when no
current is fowing/no arc.
OVERHEAD POSITION - The position in which welding
is performed from the underside of the joint, see Fig 3, 4F
and 4G positions.
OVERLAP - Weld metal at the toe of a weld which covers the
parent metal surface but is not fused to it.
OXYGEN-ACETYLENE WELDING - Gas welding in which the
heat for welding is produced by the combustion of an oxygen-
acetylene gas mixture.
PARTIAL PENETRATION - A butt weld where, by design, fusion
does not extend the full depth of the joint.
PASS - see Weld Run.
PEENING - The mechanical working of weld metal by means of
hammer blows or bombardment with shot or pellets to reduce
residual stress or distortion.
PENETRATION BEAD - Weld metal protruding through the root of
a fusion weld made from one side only.
PLASMA ARC WELDING (PAW) - A process in which the electric
arc generates a hot ionised gas stream that both shields and
transfers heat to the joint.
POROSITY - Clustered/grouped gas pores or voids in weld metal.
POROUS SLAG - A slag that has a honeycomb structure.
POSITIONER - A mechanical device manually or power operated
to hold, tilt or rotate the work to the desired position for welding.
GLOSSARY
97
CONTENTS
POST WELD HEAT TREATMENT (PWHT) - Any thermal
treatment carried out after welding.
PREHEAT - The application of heat to the parent metal
immediately prior to welding or cutting.
PULSED ARC WELDING - Welding in which pulses of current are
superimposed on a constant background current. In continuous
electrode processes the pulses control metal transfer across
the arc. Ideally, one pulse produces one droplet of molten metal
across the arc.
PULSING - Sequencing and controlling the amount of current,
the polarity, and the duration of the welding arc.
REINFORCEMENT - Weld metal lying outside the plane joining
the weld toes.
RESIDUAL WELDING STRESS - Stress remaining in a metal part
of structure as a result of welding.
RESISTANCE WELDING - A process in which two pieces of
metal are joined by placing pressure on electrodes which are
on opposite sides of the joint to be welded, maybe a spot or a
continuous weld. There is no arc with this process, the resistance
of the metal to the current fow is what causes fusion.
RMS - Root Mean Square. The effective values of measured AC
voltage or amperage. RMS equals 0.707 times the maximum, or
peak value.
ROOT FACE - The portion of a fusion face at the root which is not
bevelled or grooved, Refer to Fig 1 for examples.
ROOT GAP - The minimum distance at any cross-section
between edges, ends or surfaces to be joined, Refer to
Fig 1 for examples.
ROOT OF WELD - The points as shown in cross-section, at
which the back of the weld intersects the base metal surfaces,
see Fig 2 (a) and (b) for examples.
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CONTENTS
SHORT CIRCUITING ARC TRANSFER - Metal transfer in which
fused parts of a consumable electrode are detached in rapid
succession during repeated short circuiting contacts with the
molten weld pool. Also called short arc or dip transfer.
SILVER BRAZING - Brazing in which a silver alloy is used as
the fller metal.
SILVER SOLDERING - See Silver Brazing.
SIZE OF WELD - (a) Equal leg fllet weld - the length of the
equal sides of the largest isoceles triangle which can be inscribed
within the fllet cross-section, see leg length.
(b) Unequal leg fllet weld - the lengths of the sides containing
the angle of the largest triangle which can be inscribed within
the fllet cross section.
(c) Butt weld - the minimum depth which a butt weld extends
into a joint, exclusive of reinforcement.
SLAG INCLUSION - Slag entrapped in weld metal or between
weld metal and base metal. Only present with welding
processes that use a fux eg. MMA and SAW.
SOFT SOLDERING - see Soldering.
SOLDERING - A low strength joining process in which, during
heating, a molten Lead-Tin fller alloy is made to fow onto and
around the joint preparation. In general, the melting point of the
fller metal is less than 450C, but always below the melting
temperature of the parent metal. A fuxing agent is often used
to promote the fow of fller metal around the joint.
SPATTER - Globules of weld metal which are expelled during
welding and which do not form part of the weld.
SUBMERGED ARC WELDING (SAW) - Arc welding in which
a continuous, consumable, wire electrode (fux cored or solid) is
used and the arc is submerged under a granular fux cover, some
of which fuses to form a slag. Single or multiple electrodes in the
form of solid or tubular wires or strip may be employed, attached
to one or more power sources and feeding devices.
GLOSSARY
99
CONTENTS
TIG WELDING - Tungsten Inert Gas, see Gas Tungsten
Arc Welding.
SPRAY TRANSFER - Metal transfer which takes pace as a
rapid projected stream of droplets of diameter not larger than
that of the consumable electrode from which they are transferred.
STRESS RELIEF HEAT TREATMENT - Heating to, and if
necessary holding at, some temperature generally below the
transformation range, usually followed by slow cooling, for the
purpose of reducing internal stresses.
STRINGER BEAD RUN - A bead or run made without intentional
weaving motion.
TACK WELD - A weld (generally short) made to hold parts of
a weldment in alignment until fnal welds are deposited.
THROAT THICKNESS - (a) Actual throat thickness -
the perpendicular distance between two lines (each parallel to
a line joining the outer toes) one being a tangent at the weld
face and the other being through the further most point of fusion
penetration. Measured from the root to the weld face. Known as
the a dimension in ISO 2553.
(b) Design throat thickness - the minimum dimension of
throat thickness used for design purposes, refer to Fig 4,
(a) and (b) for examples.
TINNING - The term as applied to brazing and braze welding
defnes the deposition of a thin layer of fuxed fller metal onto joint
surfaces in order to provide a sound and strong interface between
parent metal and weld deposit.
T-JOINT - A joint between the end or edge of one part and the
face of the other part, The parts making an angle to one another
of more Than 5 degrees up to and including 90 degrees in the
region of the joint, see Fig 1, (E) and (F) for examples.
TOE - The junction between a weld face and the base metal
or between weld faces, refer to Fig 2, (C) and (d) for examples.
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CONTENTS
TOUCH OR SCRATCH START - An arc starting procedure
for TIG (GTAW). The tungsten is touched or scratched on
the workpiece; when the tungsten is lifted from the workpiece
an arc is established
TOUCH WELDING - Metal arc welding using a coated electrode,
where, as a result of a characteristic of the coating, it can be
kept in contact with the base metal during welding to facilitate
control of arc length.
TRANSFERRED ARC - A plasma arc which is struck between
a tungsten electrode and the workpiece.
UNDERCUT - A sharp groove at the toe of a weld faw which is
a run between the weld and the parent metal or in previously
deposited weld metal caused by wastage of the underlying
material, see Common Weld Defects section.
VERTICAL POSITION - The position of welding wherein the
line of the weld root is approximately vertical, see Fig 3, 3F
and 3G positions.
VISCOUS SLAG - A slag with characteristics which restrict the
fow of molten slag into the weldpool during welding.
VOLTAGE - The pressure or force that pushes the electrons
through a conductor. Voltage does not fow, but causes amperage
or current to fow. Voltage is sometimes termed electromotive
force (EMP) or difference in potential.
VOLTAGE REDUCTION DEVICE (VRD) - a device used to reduce
the OCV of welding machines to lower and safer levels
WEAVING - Transverse movement of the end of an electrode
during deposition of weld metal.
WELDING PROCEDURE - The detailed methods and practices
involved in the making of a weld eg. amps, volts, travel speed,
material and consumable type etc.
WELD FACE - The exposed surface of a weld on the side from
which welding was performed, refer to Fig 2, (C) and (d) for
examples.
GLOSSARY
101
CONTENTS
WELD JUNCTION - The boundary between the fusion zone and
the heat affected zone (HAZ) of a weld, see Fig 2, (a) and (b).
WELD METAL - All metal melted during the making of a weld and
retained in the weld, see Fig 2, (a) and (b).
WELD RUN - The weld metal resulting from one passage of an
electrode, torch or blowpipe, also called weld pass.
WIRE FEED SPEED - Expressed in in/min or mm/s, and refers
to the speed and amount of fller metal fed into a weld. Generally
speaking the higher the wire feed speed, the higher the amperage.
WORK - The material or object on which welding, brazing,
soldering or cutting is carried out. Also called workpiece..
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CONTENTS
Included
angle
(A) SINGLE-V BUTT JOINT
(C) DOUBLE-V BUTT JOINT
(E) SIBGLE BEVEL-T BUTT JOINT
(F) SIBGLE-J T-BUTT JOINT
(B) SINGLE-U BUTT JOINT
Included
angle
Angle
of bevel
Root
radius
Angle
of bevel
Root
face
Root gap
Root
face
Angle
of bevel
Included
angle
Root
face
Root
gap
Root
gap
(D) DOUBLE-U BUTT JOINT
Root gap
Root
face
Root
radius
Angle
of bevel
Included
angle
Included
angle &
angle of
bevel
Root
face
Root gap
Included
angle &
angle of
bevel
Root
face
Root
gap
Root
radius
Land
GLOSSARY
103
CONTENTS
Weld zone
Weld width
Weld
width
Weld face
Weld
face
Weld
face
Toes
Leg
(length)
Leg
(length)
Toe
Toe
Toes
Toe
Weld
zone
Fusion zone
Heat affected
zone
Parent
metal
Depth of
fusion
Fusion
face
Weld
junction
Weld
metal
Weld
metal
Heat-
affected
Zone
Fusion
zone
Root of
weld
(A) BUTT WELD
(C) BUTT WELD (D) FILLET WELD
(B) FILLET WELD
Root of
weld
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CONTENTS
PIPE BUTT WELDS
FILLET WELDS
FLAT POSITION
1F
HORIZONTAL
POSITION
2F
VERTICAL
POSITION
3F
OVERHEAD
POSITION
4F
Axis of Weld
Horizontal
Axis of Weld
Horizontal
Axis of Weld
Vertical
Axis of Weld
Horizontal
FLAT
1G
HORIZONTAL
2G
POSITION
5G
POSITION
6G
Pipe shall be
turned or rolled
while welding, Axis
of Pipe Horizontal
Pipe shall NOT be
turned or rolled while
welding, Axis of Pipe
Horizontal
Axis of pipe
Vertical
Inclined Axis with
Pipe Stationary
BUTT WELDS
FLAT
POSITION
1G
HORIZONTAL
POSITION
2G
VERTICAL
POSITION
3G
OVERHEAD
POSITION
4G
Plates Horizontal Plates Horizontal Plates Vertical Plates Vertical
45 5
L
GLOSSARY
105
CONTENTS
(A)
Design throat thickness
Actual
throat
thickness
(B)
Actual
throat
thickness
Design throat thickness
D
D

+ 0.85 D
FIGURE 4 ACTUAL AND DESIGN

THROAT THICKNESS OF TYPICAL WELDS
FIGURE 4A DEEP PENETRATION WELD AND
DESIGN THROAT THICKNESS TO AS 1554.1
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CONTENTS
ADD
107
CONTENTS
O
X
Y
-
A
C
E
T
Y
L
E
N
E

F
L
A
M
E

A
D
J
U
S
T
M
E
N
T

FLAME ADJUSTMENTS FOR OXYGEN ACETYLENE WELDING
For oxy-acetylene welding there are essentially four main types of
fame adjustments used for welding a wide variety of base metals.
A neutral fame is the most common setting used for the majority of
fusion welding and braze welding applications. The following diagrams
are intended as a guide to the easy identifcation of these fame types
and their use with specifc base metals.
OXY-ACETYLENE
FLAME ADJUSTMENT
(A) OXIDISING FLAME
Small inner cone
Bright inner cone
(B) NEUTRAL FLAME
Bright acetylene feather
(D) CARBURIZING FLAME
Small pale green feather
(C) REDUCING FLAME
For welding Copper and
certain Copper based alloys
For welding Steel, Stainless
Steel, Cast Iron, Aluminium
and Copper etc.
For welding Aluminium
and Low Alloy Steel etc.
Suitable for silver brazing,
soldering and many hard
surfacing applications.
108
CONTENTS
Welding symbols are the shorthand of welding, they provide a
concise means of relaying information on engineering drawings.
Detailed information such as the type, size, orientation and
fnishing requirements of the weld joint can be communicated.
Welding symbols do not always contain all the information
required for welding. Reference is often given on the welding
symbol, to a specifcation, process, procedure or other document
which provides the necessary data to complete the welding
operation.
The use of welding symbols result in the following benefts:
1.The complete translation of specifc design requirements to the
workshop; regarding such parameters as weld sizes, processes
to be used, joint preparations etc thus allowing the welding task
to be complete as per instruction.
2.The elimination of unnecessary and incomprehensible
details on drawings-when such details specify weld type, size,
length, pitch etc.
3.The establishment of a common understanding of design intent
and welding prerequisites between designers, workshop welder/
inspectors, welding engineers, Q.A./Q.C personnel and code
authorities etc.
4.Standardisation, within and across the welding, fabrication
and construction industries.
BASIC SYMBOLS
There are different standards for welding symbols. The following
pages are set out using the International Standard ISO2553
(Welded, brazed and soldered joints - Symbolic representation
on drawings) and the Australian Standard AS1101.3 (Graphical
Symbols for General Engineering - Welding and Non-Destructive
Examination) which is based on the American Welding Society
Standard. AWS A2.4 In AS1101.3, a clear distinction is made
between the terms weld symbol and welding symbol. The term,
weld symbol describes the type of weld to be deposited see
FIGURE 6A for the basic weld symbols in common use. The
welding symbol is a method of representing the weld symbol on
drawings and includes all the relevant information and references
necessary to complete the welded joint.
WELDING SYMBOLS
109
CONTENTS
W
E
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D
I
N
G

S
Y
M
B
O
L
S
ELEMENTS OF A WELDING SYMBOL TO AS1101.3
The major elements are:
(a) Reference line (shown horizontally)
(b) Arrow
(c) Basic weld symbols
(d) Dimensions and other data
(e) Supplementary symbols
(f) Finish symbol
(g) Tail
(h) Specifcation, process, or other references
Refer to Figure 5 for the standard location of these
elements on a welding symbol.
110
CONTENTS
WELDING SYMBOLS
F
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G
U
R
E

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(
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S I D E
O T H E R
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(
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1
1
1
0
-
c
0
7
5
( )
( )
( )
111
CONTENTS
W
E
L
D
I
N
G

S
Y
M
B
O
L
S
Weld All
Around
Site Weld
Complete
Penetration
From One
Side
Backing
Or Spacer
Material
Surfacing Convex Concave
Fillet
Weld
Plug
Weld
Or Slot
Weld
Spot Weld
Or Projection
Weld
Seam
Weld
Backing
Run Or
Backing
Weld
Surfacing
Edge
Weld
Stud
Weld
BUTT WELD
Square Scarf V Bevel U J Flare V
Flare
Bevel
FIGURE 6B SUPPLEMENTARY SYMBOLS
FIGURE 6A BASIC WELD SYMBOLS
112
CONTENTS
WELDING SYMBOLS
(D) COMBINED FILLET AND BUTT WELD IN T-JOINT
WITH SPECIFIED ROOT GAP.
Symbol
(3)
5
2 3
5
5
Desired weld
2
(3)
(C) STAGGERED INTERMITTENT FILLET WELDS.
75-250
75-250
75
250
C Weld C Weld
Desired welds
C Weld C Weld
125 125
75 75 75
(B) UNEQUAL DOUBLE-FILLET WELDS.
6
12
Symbol
Desired weld
12
12
6
6
(A) SINGLE-FILLET WELD
8
Symbol
Desired weld
8
8
113
CONTENTS
W
E
L
D
I
N
G

S
Y
M
B
O
L
S
(A) PARTIAL PENETRATION, SINGLE-V BUTT WELD
(B) FULL PENETRATION
6
90
6 (10)
Desired Weld (D=10) Symbol
90
Desired Weld
Note
overlap
Symbol
Note: The total design throat
thickness (D)=22mm
90
5
5
22
(D=12)
5 (12)
90
90
5 (12)
See
Note
(D=12)
90
Desired
Weld
Symbol
Note: The total design throat
thickness cannot be greater than
plate thickness (10mm)
See
Note
(4)
(7)
2
60
(4)
60
10
(7)
2
Symbol
(D) COMBINED FILLET AND BUTT WELDS
9
70
70
9
6 (14)
6 (14)
Desired Weld
9 9
6 6
25
70 70
14
14
Note
overlap
(C) SINGLE BEVEL BUTT WELD WITH ROOT OPENING
114
CONTENTS
WELDING SYMBOLS
Symbol
See
Note
NOTE: See drawing for
dimensions and orientation
12
45
45
12
Section of desired weld
Symbol
Desired weld
3
3
(A) SURFACE WELD
(B) PLUG WELD
(D) SEAM WELD
115
CONTENTS
W
E
L
D
I
N
G

S
Y
M
B
O
L
S
(D) SEAM WELD
(C) SPOT WELD
Symbol
RSW - Resistance spot welding
Desired weld
Section A-A
24 24
12 12
6
12
RSW
6 24
(5)
A
A
24 24
+ + + + +
Min acceptable shear
strength 35 N/mm
Desired weld Section A-A

Symbol
EBW - Electron-
beam welding
A
A
EBW
35 N/mm
116
CONTENTS
A GUIDE TO INTERPRETING THE AUSTRALIAN / NEW
ZEALAND STANDARD CLASSIFICATION FOR LOW
CARBON STEEL MMAW ELECTRODES
The Australian/New Zealand Standard 4855 for Manual Metal Arc
Welding of non-alloy and fne grain steel is identical to ISO 2560
standard, and is to supersede AS/NZS 1553.1.
Under the new AS/NZS 4855 standard, covered electrode can be
classifed based upon either yield strength and 47J minimum impact
energy known as method -A, or tensile strength and 27J minimum
impact energy known as method -B, which the second method is
widely accepted in Australian market. For details of the complete
range of classifcations, please consult AS/NZS 4855.
AS/NZS 4855-B - E49 16 A U H10
Compulsory
clalssifcation designators
Specifcation number
Classifcation by tensile
strength and 27J CVN
requirement
Covered electrode
Deposit metal tensile strength.
49 indicates minimum
tensile strength of 490 N/mm
,

other designator like 43, 55
or 57 is often used
Type of flux coating
Condition of heat treatment.
The symbols A and/or
P are used to indicate
the as-welded and/or heat
treated condition/s
Optional supplemental
designators
Diffusible hydrogen. H5,
H10,H15 is used to indicate
a maximum diffusible
hydrogen content of 5,10,
and 15 ml/100g of deposited
metal, respectively
designators
47J impact energy
at the normal
27J test temperature
has also been met.
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CONTENTS
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A GUIDE TO INTERPRETING THE AMERICAN ANSI / AWS
SPECIFICATION FOR CARBON STEEL ELECTRODES FOR
SHIELDED METAL ARC WELDING
The ANSI/AWS A5.1 Specifcation for Shielded Metal Arc Welding
details classifcations covering general purpose, iron powder and
low hydrogen electrodes. The classifcation system consists of
an alphanumeric group followed by a group of optional designators.
Please consult ANSI/AWS A5.1 for further details on the range.
1ST GROUP
Minimum Weld Metal
Strength
Tensile Yield Elongation
ksi ksi %
60 48 22
70 58 22
2ND GROUP
Welding Position,
Welding Current
and Coating Type
ie EXX12, EXX24
and EXX18
For details refer
to the Usability
Digits of Major
Classifcations
on next page.
3RD GROUP
Optional Designator for
Improved Impact Toughness
E7016-1=20 ft.lb
@ -50F av.min.
E7018-1=20 ft.lb
@ -50F av.min.
E7024-1=20 ft.lb
@ -0F av.min.
3RD GROUP
Optional Diffusible Hydrogen
Designator indicates that the low
hydrogen electrode meets the
requirements of the diffusible
hydrogen test.
H4 <4mL/100g)
of deposited weld metal
H8 <8mL/100g)
H16 <16mL/100g)
3RD GROUP
Optional Coating Absorbed
MoistureDesignator indicates
that the coating of a low hydrogen
electrode is moisture resistant after
being exposed to an environment
of 80F and 80% relative humidity
for a period of not less than 9
hours. Maximum specifed
moisturecontents are detailed in
Table 10 of thespecifcations.
E XX XX XHXR
ELECTRODE
3RD GROUP
Optional designators
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CONTENTS
USABILITY DIGITS OF MAJOR CLASSIFICATIONS INDICATING
TYPE OF POSITIONS AND CURRENT TYPE REQUIREMENTS
USABILITY
CLASSIFICATION
WELDING
POSITIONS
TYPE OF CURRENT
AND POLARITY
TYPE OF
COVERING AND
SLAG
10 F,V,OH,H
D.C. electrode
positive
High cellulose
11 F,V,OH,H
A.C. or D.C.
electrode positive
High cellulose
12 F,V,OH,H
A.C. or D.C
electrode positive
or negative
High titania
viscous slag
13 F,V,OH,H
A.C. or D.C
electrode positive
or negative
High titania viscous
slag
14 F,V,OH,H
A.C. or D.C
electrode positive
or negative
Low iron powder
15 F,V,OH,H
D.C. electrode
positive
*Hydrogen
controlled
16 F,V,OH,H
A.C. or D.C.
electrode positive
*Hydrogen
controlled
18 F,V,OH,H
A.C. or D.C.
electrode positive
*Hydrogen
controlled basic,
low iron powder
19 F,V,OH,H
A.C. or D.C
electrode positive
or negative
Limenite
20 F,H, Fillet
A.C. or D.C.
electrode positive
High iron oxide
24 F,H, Fillet
A.C. or D.C
electrode
positive or negative
High iron
oxide titania
27 F,H, Fillet
A.C. or D.C
electrode positive
or negative
*Hydrogen
controlled powder
iron oxide
28 F,H, Fillet
A.C. or D.C.
electrode positive
*Hydrogen
controlled low iron
powder basic
46
F,V-down
OH, H
A.C. or D.C.
electrode positive
*Hydrogen
controlled basic
48
F,V-down
OH, H
A.C. or D.C.
electrode positive
*Hydrogen
controlled basic,
low iron powder
99
As
specifed
As Specifed by
manufacturer
As Specifed by
NOTE: The abbreviations, F, V, V-Down, OH, H, and H-FiIIet indicate the following welding positions:
F-Flat, V-Vertical, V-down - Vertical down, OH-Overhead, H-Horizontal, H-fllet-Horizontal fllet. *Unless
otherwise indicated the classifcation digits have wide usage amongst the Australian AS, USA (AWS),
Canadian (CSA), Japanese (JIS) and the new draft ISO Standards. European Economic Community
Standards (CEN). As national standards are subject to regular revision these situations could alter.
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CONTENTS
USABILITY DIGITS OF MAJOR CLASSIFICATIONS INDICATING
TYPE OF POSITIONS AND CURRENT TYPE REQUIREMENTS
A GUIDE TO INTERPRETING THE AUSTRALIAN STANDARD
CLASSIFICATION FOR HIGH STRENGTH STEEL MMAW
The Australian/New Zealand Standard 4857 for Manual Metal Arc
Welding of high-strength steesl is identical to ISO 18275 standard,
and is to supersede AS/NZS 1553.2.
Under the new AS/NZS 4857 standard, covered electrode can be
classifed based upon either yield strength and 47J minimum impact
energy known as method -A, or tensile strength and 27J minimum
impact energy known as method -B, which the second method is
widely accepted in Australian market. For details of the complete
range of classifcations, please consult AS/NZS 4857.
AS/NZS 4857-B - E62 18-G A U H10
Compulsory
clalssifcation designators
Specifcation number
Classifcation by tensile
requirement
Covered electrode
Deposit metal tensile strength.
62 indicates minimum
tensile strength of 620 N/mm
,

other designator like 59, 69,
76, 78 or 83 is often used
Type of flux coating
Any other agreed chemical
composition
Condition of heat treatment.
The symbols A and/or
P are used to indicate
the as-welded and/or heat
treated condition/s
designators
Diffusible hydrogen. H5,
H10,H15 is used to indicate
a maximum diffusible
hydrogen content of 5,10,
and 15 ml/100g of deposited
metal, respectively
designators
47J impact energy
at the normal
27J test temperature
has also been met.
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CONTENTS
A selection of designators for nominal alloy weld metal
compositions widely used in ISO, Australian (AS) European
and American (AWS) systems of classifcation for electrodes
and weld metal. See the appropriate Standard for the fully
specifed composition requirements and the location(s) of the
designator in the classifcation.
ALLOY GROUP DESIGNATOR
NOMINAL COMPOSITION
REQUIREMENTS
Carbon -
Molybdenum
A1 0.40 - 0.65Mo
Chromium -
Molybdenum Steels
B1
B2 or B2L
B3 or B3L
B6 (5Cr)#
B7, B7L (7Cr)#
B8, B8L (9Cr)#
0.50Cr 0.5Mo
1.25Cr 0.5Mo
2.25Cr 0.5Mo
5Cr 1Mo
7Cr 5Mo
9Cr 1Mo
Nickel Steels
Ni1, Ni3L or C3
Ni2, Ni2L or C1, C1L
Ni3, Ni3L or C2, C2L
NM
1 Ni
2.5 Ni
3.5 Ni
1 Ni 0.5Mo
Manganese
Molybdenum Steels
D1
D2
1.5 Mn 0.35 Mo
1.8 Mn 0.35 Mo
Mil. Spec. Type Low
Alloy High Tensile
Series, AS 1553.2
and AWS A5.23
Examples
M (eg. E7618-M)
M1, M2, M3, M4
eg. F9A2-
ECM1-M12)
A series of Mn-Ni-Cr-Mo
specifed compositions
for various strength levels
Refer to standards
Other Low Alloy
Steels of specifed
composition (SAW
and FCAW
standards
EF1-EF6 series
F1-F6 series
K1-K7 series
SAW Electrodes
SAW Weld metals
FCAW Weld metals
Refer to AWS Standards
Weathering Steels
(Corten - Austen
etc.)
W, W1, W2
Ni-Cr-Cu steels
typically 0.5Ni-0.5Cr 0.5Cu
Alloy unspecifed G, GS
Composition exceeds
minimum requirements in at
least one specifed element.
L variants are a low carbon version (usually 0.05 % max) of
the standard alloy carbon range
# Alternative designators in some AWS standards.
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DESCRIPTION OF MMAW ELECTRODE TYPES AS CLASSIFIED
BY NATIONAL AND INTERNATIONAL STANDARDS
EXX10 AND EXX11 TYPES (AUSTARC 11)
Electrodes of these classifcations have thin coatings which
contain at least 15% cellulose and up to 30% titania as rutile or
titanium white. The group is characterised by a forceful, deeply
penetrating, spray type arc with fairly high spatter. A voluminous
gas shield is produced, as a result of decomposition of the
cellulose materials in the arc region, which protects the weld
metal from atmospheric contamination. High weld metal quality
(including radiographic soundness) is achieved in all welding
positions and the electrodes operate satisfactorily from AC or DC
(electrode positive) power sources for EXX11 types and from DC
(electrode positive) only for EXX10 types.
EXX12 TYPE (AUSTARC 12P)
Electrodes of this classifcation have thin coatings which contain a
high proportion of titania as rutile, ilmenite or titanium white. The
group is characterised by a quiet, medium penetrating arc with
low spatter. The slag is viscous, full covering and easily removed
when cool. General ease of handling in all welding positions and
an ability to bridge gaps in work having poor ft-up are features
common to this electrode type. Due to the viscous slag, many of
these electrodes are suitable for use in the vertical down position.
In Europe, rutile-cellulose is a common designation, while in the
AWS classifcation sodium binders are specifed.
EXX13 TYPE (AUSTARC 13S)
Electrodes of this classifcation are similar in formulation to the
EXX12 group. However, basic materials are added to increase
the fuidity of the slag. Similar to EXX12 electrodes, they operate
with a quiet medium-penetrating arc with low spatter. The slag is
fuid, full covering and easily removed when cool. The fuid slag
makes this electrode ideal for fllet welding in the fat or horizontal,
vertical-up and overhead welding positions. Potassium binders
give improved arc stability and are specifed for the
AWS classifcation. (cont. over)
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EXX14 TYPE
Electrodes of the EXX14 type have medium thick coatings,
containing a high proportion of titania and suffcient iron powder to
ensure a deposition effciency of 105 - 130%. They operate with
a smooth, medium penetrating arc with low spatter. The slag is
fairly viscous, full covering and easily removed when cool. These
electrodes are suitable for both single-run and multiple-run welds
in all positions and can be used to bridge gaps in work having
poor ft-up. Due to the viscous slag, many of these electrodes are
suitable for use in the vertical down position.
EXX15 TYPE
The original basic low hydrogen type is suitable for use on
DC electrode positive only. Similar characteristics and
application to EXX16 and EXX18.
EXX16 TYPE (AUSTARC 16TC)
These electrodes have a chemically basic slag, generally of
the limestone-fuoride type similar to the EXX15 group but with
the ability to run on AC as well as DCEP Higher arc stability
is provided by the use of potassium silicate binders and other
potassium bearing materials in the coating. Coating materials are
inorganic, selected for minimal combined moisture and coverings
are baked at a high temperature to provide low hydrogen in the
arc atmosphere.
Basic coated electrodes are noted for their tough low oxygen weld
metals and suitability for welding a wide range of carbon and low
alloy steels. The fuid full covering slag gives slight convex beads
and excellent all position welding capabilities.
EXX18 TYPE (AUSTARC 18TC AND AUSTARC 77)
Similar coating type and operational characteristics to the EXX16,
but the somewhat heavier coating contains suffcient iron powder
to give increased deposition effciency to 105-130%. This still
permits all position welding on AC or DCEP but the presence of
the iron powder also improves metal transfer and operational
characteristics. The EXX18 group are widely used in a range of
steels and critical applications where weld quality is the main
requirement, particularly in all position welding. The group also
serves as the major basic group for a wide range of low alloy high
tensile electrodes.
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CONTENTS
EXX19 TYPE
The slag type is based on the titanium oxide-iron oxide mineral,
ilmenite, and therefore has similarities to the EXX12 & 13 types
but with some distinct differences. Characterised by fuid slag and
forceful arc it gives Grade 1 radiographic standards, good ductility
and toughness down to -20C.
EXX20 TYPE
A high iron oxide-manganese oxide/silicate type slag giving a
spray type arc and smooth fat to concave welds. Easily removed
honeycomb type brittle slag.
EXX24 TYPE (AUSTARC 24)
Similar slag type to EXXl2, 13 & 14 but with larger proportion of
iron powder and heavier coating, approximating some 50% of
electrode weight. High deposition rate, high speed runs and high
effciency in the 130 to 150% class.
EXX27 TYPE
Electrodes of this type have thick, heavy coatings which contain
a high proportion of iron and manganese oxides and/or silicates,
and suffcient iron powder to ensure a deposition effciency
greater than 130%. They operate with a vigorous, spray type arc
with medium to deep penetration. The slag is fuid, voluminous,
full covering and when cool well honeycombed on the underside,
friable and easily removed. Electrodes of this type are suitable
for high speed welding applications in the fat and horizontal-fllet
positions where good penetration and easy deslagging
are essential.
EXX28 TYPE
A heavy coated high iron powder version of the basic coated
lime fuorspar EXX18 electrode. The coating usually contains
approximately 50% of the weight of the electrode, restricting its
use to the fat and horizontal fllet positions.
EXX46 AND EXX48 TYPES
Electrodes of the EXX46 and EXX48 classifcations have
respectively the same usability, composition and design
characteristics as EXX18, except for excellent vertical-down
performance.
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CLASSIFICATION FOR FERRITIC STEEL GMAW ELECTRODES
The standard AS/NZS 2717.1 for Gas Metal Arc Welding Ferritic
Electrodes is the only AS/NZS standard for semi-automatic welding
process that has not been superseded by ISO standards. Previous
FCAW stand AS 2203.1 has been supersended by AN/NZS ISO
17632, 17634 and 18276. The system of classifcation consists of
three alphanumeric groups separated by the hyphens, which may
be summarised as follows. For full details of the complete range of
classifcations, testing, chemical, mechanical, radiographic and other
requirements of the standard, please consult AS/NZS 2717.1.
AS 2717.1 ES6 - GC - W 50 3 A H
2ND GROUP
Type of external
shielding gas First
digit is G for gas.
C = shielding with
welding grade
carbon dioxide
M = shielding with
mixed gases.
I = shielding with
inert gas.
3RD GROUP
Weld metal properties.
A indicates as-welded
condition, or
P after post weld
heat treatment
H indicates hydrogen
controlled weld metal.
AS WELDED TENSILE PROPERTIES*
Weld Metal
Classifcation
Min. Tensile
Strength
Min.Yield
Strength
Min.
Elongation
on 5d
W50XH 500 MPa 360 MPa 22%
W559H 550 MPa 470 MPa 19%
For complete details refer to AS / NZS 2717.1
FIRST GROUP - ES = Electrodes, Solid,
followed by a numerical or alphanumerical
code which defne the chemical composition of
the wire. For example
Wire
Class.
C Mn Si Other
ES3
ES4
ES5
ES6
ES7
.06-.15
.07-.15
.06-.19
.06-.15
.07-.15
.90-1.40
1.00-1.50
.90-1.40
1.40-1.85
1.50-2.00
.45-.75
.60-.85
.30-.60
.80-1.15
.50-.80
-
-
.50-90AI-
-
ESB2L
ESNi2
ESD2
ESM3
ESMG
ER70S-G
Low carbon Cr-Mo Alloy
2.5 Ni Alloy
Mn-Mo-Alloy
Mn-Ni-Cr-Mil Spec Alloy
o specifed composition
Refer AS / NZ 2717 for full range of
classifcations and compositions.
The third digit, for carbon
steel electrodes, indicates
the Impact energy grade
number as specifed below.
For low alloy, ferritic steel
electrodes, the third digit is
9 and the minimum average
CVN impact values are as
stated in AS / NZS 2717.1.
Impact
Energy
Grade #
Min. Avrge
Charpy V notch
impact value
Z Not required
A 47J at +20
0 47J at 0
2 47J at -20
4 47J at -40
6 47J at -60
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A GUIDE TO INTERPRETING THE ANSI /AWS GAS SHIELDED
ARC WELDING FILLER METAL SPECIFICATION
The ANSI / AWS A5.18 specifcation for Carbon Steel Electrodes
and Rods for Gas Shielded Arc Welding includes Metal Cored
electrodes formerly classifed in ANSI / AWS A5.20 and an example
is illustrated to acquaint the user with information provided by the
specifcation.While the full range of classifcations can be employed
with GMAW only solid rods should by used for GTAW (TIG) and
PAW processes. For full details of all test requirements, radiographic
standards, manufacturing tolerances, packaging etc refer to the
latest edition of the standard.
E R 7 0 S - 6 H 4
E R 7 0 C - 6 M H 4
LETTER
DESIGNATORS
E = Electrode
R = Rod
S = Solid Wire
C = Composite Metal
Cored Wire
M = Mixed Shielding
Gas
C = Cabon Dioxide
Shielding Gas
OPTIONAL
DESIGNATORS
Indicate diffusible
weld metal
hydrogen content
H4 = <4mL/100g)
H8 = <8mL/100g)
H16 = <16mL/100g)
AS WELDED TENSILE PROPERTIES*
Weld Metal
Classifcation
Min. Tensile
Strength
Min. Yield
Strength
Min.
Elongation
%
psi MPa psi MPa
ER 70-X 70,000 480 58,000 400 22
ER 70-XX 70,000 480 58,000 400 22
*Properties as detailed are appliccable for all classifcations
DEPOSITION PROCESS
Class C Mn Si Other
ER70S-2
ER70S-3
ER70S-4
ER70S-5
ER70S-6
ER70S-7
0.07
0.06-0.15
0.07-0.15
0.07-0.19
0.06-0.15
0.07-0.15
0.90-1.40
0.90-1.40
1.00-1.50
0.90-1.40
1.40-1.85
1.50-2.00
0.40-0.70
0.45-0.75
0.60-0.85
0.30-0.60
0.80-1.15
0.50-0.80
Ti, Zr, AI
0.50 Cu
0.50 Cu
Cu, Al
0.50 Cu
0.50 Cu
ER70S-G Agreed between the supplier & customer
WELD METAL ANALYSIS
E70C-3X 0.12 1.75 0.90 0.50 Cu
E70C-6X 0.12 1.75 0.90 0.50 Cu
E70C-G Agreed between the suppler & customer
E70C-GS(X) Agreed between the suppler & customer
Single fgures are maximum
G- general, GS = general, single pass only
DEPOSITION PROCESS
Class Ftlb J
ER70S-2
ER70S-3
ER70S-4
ER70S-5
ER70S-6
ER70S-7
ER70S-G
ER70S-3X
ER70S-6X
ER70S-
G(X)
ER70S-
GS(X)
20 @ -20F
20 @ 0F
N/A
N/A
20 @ -20F
20 @ -20F
As Agreed
20 @ 0F
20 @ -20F
As Agreed
N/A
27 @ -29F
27 @ -18F
N/A
N/A
27 @ -29F
27 @ -29F
As Agreed
27 @ -18F
27 @ -29F
As Agreed
N/A
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EXAMPLES:
1. AWS A5.18: ER70S-6
Indicates a solid wire electrode and fller rod. Mechanical testing
of an all weld metal test plate, deposited under CO
shieldng will
give min. 72 ksi (500 MPa) tensile strength, 60 ksi (420 MPa) yield
strength, min. 22% elongation on 4D and a charpy impact strength
of 27J at - 29C. The weld will meet radiographic requirements. The
wire meets a specffed chemical analysis, dimensional requirement
and some additional testing where supplied as a fller rod only.
2. AWS AS.28: ER80S-B2
Indicates a solid wire electrode and fller rod. Mechanical testing of
an all weld metal deposit, welded under Argon+1-5% O
gas
shielding is carried out after PWHT at 620C. The requirements are a
min. tensile strength of 80 ksi (550 MPa) yield strength at 0.2% offset
of 68 ksi (470 MPa) and an elongation 19% min. on 4D. It has to
meet radiographic soundness but no impact properties are specifed
for this alloy. The wire, a nominal 1.25% Cr/0.5% Mo alloy must meet
a specifc composition analysis, dimensional requirements and some
addtional requirements for supply as a fller rod only.
3. AWS A5.28: E80C-B2
A cored or composite electrode the dropping of the R indicates
it meets the specifcation for an electrode only. It meets all the
weld metal soundness and mechanical requirements specifed in
example 2 above but the B2 alloy specifc composition is confrmed
by anaysis of the deposited weld metal.
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A GUIDE TO INTERPRETING THE AS/NSZ ISO SPECIFICATIONS
FOR FLUX CORED ARC WELDING
The new AS/NZS ISO 17632 standard is a series of adopted ISO
standards to cover Flux Cored Arc Welding (FCAW) electrodes
for Non-alloy and fne grain steels. The following provides a brief
introduction into the classifcation systems, and the standard series
cover different electrode range. For full classifcation details, please
consult the latest standards.
AS/NZS ISO 18276: high strength Steels
AS/NZS ISO 17634: creep resisting steels
AS/NZS ISO 17633: Stainless steels.
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AS/NZS ISO 17632-B - T 55 4 T5-1 M A-N2-U H5
Optional supplemental designators
47J impact energy at the normal 27J
test temperature has also been met.
Diffusible hydrogen. H5,H10,H15
is used to indicate a maximum
diffusible hydrogen content of 5, 10
and 15 ml/100g of deposited metal,
respectively.
Classification by tensile
requirement
Tubular cored electrode
Minimum tensile strength
meets 550MPa
Tested temperature @
-40C meets the minimum
impact properties of 27J
Usability designator. T5
indicates Lime-flouride
flux, and generally referes
to Basic flux system
Welding position. 1
indicates all positional;
and 0 - downhand only.
Shielding gas M
indicates mixed gases
Indicates tested in the
as welded condition
chemical composition
designator, N2 indicate
2%Nil in deposited weld
metal
Compulsory clalssifcation designators
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CONTENTS
A GUIDE TO INTERPRETING THE ANSI / AWS SPECIFICATIONS
FOR FLUX CORED ARC WELDING
The ANSI / AWS A5.20 (Plain Carbon) and A5.29 (Low AlIoy)
Electrode specifcations have similar classifcation systems. They are
shown in a combined form to acquaint the user with the information
provided by the classifcation. For full details of all test requirements,
radiographic standards, manufacturing tolerances, packaging, weld
metal compositions etc., please consult the latest edition of the
appropriate specifcation
WELD METAL
COMPOSITION
Electrodes to A5.20 have a weld metal
composition requirement that ensures they
are plain carbon steels and do not employ
an alloy suffx. Electrodes to A5.29 have
specifc compositions and employ the
designations as shown in Table 4 of this
section (Page 126). These include the
A1, B2, B3, Ni1, Ni2, D1, D2, D3, K1 to
K7: W types.
For full details of the chemical
compositions, refer to Table 1 of A5.29
IMPACT STRENGTH
The A5.20 classifcation EXXT-1, T-5,
T-6 & T-8 have min. impact requirements
shown in the usability table. In A5.29
the requirement for impact testing on
as-welded or PWHT specimens and the
test temperature for min. 20ft-lb (27J) is
specifed in Table 4 against the complete
classifcation eg.
E81T1-Ni2 AW-40F (40C)
E80T5-Ni2 PWHT - 75F (-60C)
USABILITY AND
PERFORMANCE
Note: A5.20
Classifcations shown
here are T-X, A5.29 as
TX. For details of usability
and performance refer to
Page 135.
POSITIONAL
CAPABILITIES
0 = Flat and Horizontal
1 = All Positions
TUBULAR
Flux Cored Electrode
ELECTRODE
WELD METAL
STRENGTH DIGITS
The strength digits 6 and 7 in
A5.20 and 6, 7, 8, 9, 10,
11 and 12 in A5.29 represent
0.1 of the min. tensile strength in
ksi, eg. 8=80ksi (550MPa)
11=110ksi (760MPa)
Each strength group has a min.
yield strength, 12ksi (10ksi for
6 in A5.29) below the min.
tensile strength and a min.
elongation requirement.
AWS A5.20 E X X T - X
AWS A5.29 E X X T X - X
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CONTENTS
USABILITY AND PERFORMANCE CAPABILITIES
CLASSIFICATION
T-1, T1 - Almost invariably a Rutile (Titania) based fux imparting
smooth running, spray transfer, low spatter using CO
shielding,
electrode positive. Some designed for out of positioning welding
when Argon/CO
mixtures may be preferred. Most popular group.

E7XT-1 - Has impact requirement of 20ft-lb (27J) at 0F. (-18C).
T-2 - Essentially similar to T-1 but higher Mn and Si for improved
single pass welding over mill scale, rust or on rimmed steel in the
fat and horizontal fllet positions.
T-3 - Self shielded, high speed single pass welds on sheet metal
up to 5mm thick using DCEP.
T-4, T4 - Self shielded, very high deposition rate with globular
transfer on DCEP. Low penetration, desulphurised welds, resistant
to cracking, can be used on poor ft up. Suitable single or multiple
run in fat and horizontal positions.
T-5, 15 - Lime Fluoride basic fux for high toughness and
crack resistance using DCEP and CO
shielding. Argon/CO

mixtures may be preferred for some applications.Globular
transfer, convex beads (similar E7016-18 electrodes) for critical
fat and horizontal fllet welds. Impact requirement for EXXXT-5
is 20ft-lb. (27J) at -20F (-29C).
T-6 - Self shielded, DCEP, spray type transfer for single or multiple
pass welding in fat or horizontal positions. Provides good low
temperature impact properties 20ft-lb (27J) at -20F (-29C) and
root penetration, easy slag removal in fat and horizontal positions.
Single or multipass welds,
T-7 - Self shielded, DCEN, single and multipass pass welds with
desulphurising slag giving crack resistant welds. Larger sizes give
high deposition rates, small sizes provide all position welding.
T-8, T8 - Self shielded, DCEN, all position welding, single and
multipass. The slag system produces good impact properties
(T8 min. 20ft-lb (27J) at -20F (-29C). and a desulphurised weld
metal resistant to weld cracking.
T-10 - Self shielded, DCEN, single pass welding at high travel
speeds in the fat, horizontal, down slopes (to 20).
T-11 - Self shielded, DCEN, with a smooth spray arc, General
Purpose electrodes for single and multipass welding in all
positions and high travel speed welding.
T-G, TX-G - A classifcation for new multipass electrodes not
covered by any of the above.
T-GS - A classifcation for new single pass electrodes not
covered by any of the presently defned classifcations.
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CONTENTS
STANDARDS AUSTRALIA AND THE ANSI/AWS
SPECIFICATION STANDARDS FOR STAINLESS STEEL
AND ALUMINIUM ALLOY ELECTRODES
The new AS/NZS standards offer two classifcation systems, which
are according to nominal composition (-A) and alloy type (-B)
respectively. In Australia market, the B system is widely accepted
and substantially the same to AWS standards.The following provides
a brief introduction into the classifcation systems employed and the
information they provide to the user. These are:
ANSI/AWS A5.4 - Stainless Steel MMAW ELECTRODES - AS/NZS 4854
ANSI/AWS A5.9 - Stainless Steel GMAW ELECT. - AS/NZS ISO 14343
ANSI/AWS A5.10 - Al./Al. Alloy GMAW - AS/NZS ISO 18273
For full details of the manufacturing tolerances, testing
requirements, packaging, chemical composition and other
aspects of the standard specifcations, please consult the latest
edition of the appropriate above standard.
1. CORROSION-RESISTING CHROMIUM AND CHROMIUM-
NICKEL STEEL ELECTRODES (a) MMAW COVERED
ELECTRODES - AS/NZS 4854-B and ANSI/AWS A5.4
The basis of these classifcations is the chemical composition
and mechanical properties of the deposited metal, the coating type
and current.The system of designation is as follows:
COATING TIME
-15 DC Electrode Positive Lime Type
-16 AC or DCEP Lime or Rutile Type
-17 AC or DCEP Acid Rutile Type
-25 DC EP Heavy Coated Lime Type
-26 AC or DCEP Heavy Coated Rutile Type
An alphanumeric system
of alloy designation almost
universally employed. eg.
308, 316L, 309Mo, 310 etc.
X X X - X
ELECTRODE
E
ALLOY DESIGNATION
The -17, -25, and -26 suffxes are recent additions to the
classifcations. The -17 is a more siliceous version of the -16.
The -25 and -26 coatings are designed for fat and horizontal
welding and are generally synthetic versions using lower alloyed or
plain carbon core wires. (b) GMAW ELECTRODES The Standards
Australia AS/NZS ISO 14343 for gas metal arc electrodes bases its
classifcation of the electrode range on the composition of the solid
wire. This is followed by the commonly employed alphanumeric
designation of the chromium nickel steel, the actual composition of
which is specifed in the standard.
131
CONTENTS
No mechanical properties are specifed. The ANSI/AWS A5.9
Specifcation covers solid wires, and metal cored, stranded or
composite wires and again bases its classifcation on the chemical
composition of the solid wires or a fused sample of the cored
or composite wires. This specifcation covers electrodes or fller
metals for GMAW, GTAW or SAW processes. For this reason, no
mechanical testing requirements are specifed. The designations
in the classifcations differ slightly.
2. ALUMINIUM AND ITS ALLOYS GMAW ELECTRODES
The AS/NZS ISO 18273 and ANSI / AWS A5.10 standards
specifcations for Aluminium and Aluminium alloys GMAW
electrodes (and in the case of A5.10, fller rods) both base their
classifcation on the chemical composition of the solid wire. The
alloy is designated by an internationally accepted system involving
a four digit number, the frst indicating the aluminium content or
the main alloying element, Of these, the following are employed in
welding as electrodes or fller rods, viz.
1XXX = Aluminium content 99% min.
2XXX = Copper is main alloying element
4XXX = Silicon is main alloying element.
5XXX = Magnesium is main alloying element.
The second digit indicates modifcations to the basic alloy
or impurity limits while the third and fourth digits identity the
aluminium alloy or indicate the aluminium purity.
A prefx of E indicates an electrode wire in the Australian Standard
and ER indicates Electrode/Filler Rod in the ANSI / AWS System.
Example:- E5356 and ER5356 are classifcations for a popular
4.5-5.5% Mg aluminium alloy with minor additions of Mn, Cr and Ti
and limits on Si,Fe,Cu,Zn and others.
Modifying the alloy designation to 5556 indicates mainly a rise in
Mn level from approximately 0.1 to 0.5-1.0% and marginally higher
aim value for Mg and Zn (0.1 max to 0.25 max.), which results in
a higher tensile strength deposit.
Alloy E5183 and ER5183 has become a popular fller metal used
in the fabrication of marine passenger, car ferry and pleasure
craft. It is a modifcation of the 5356 alloy with increases in Si, Mn
and Zn and is particularly suitable for welding 5083 alloy in marine
applications because of the higher tensile strength weld metal.
The composition of the wires in both standards are almost identical
with slightly narrow tolerance on Beryllium content from AWS
standard and an electrode fully meeting the requirements of AWS
A5.10 will be deemed to be qualifed to the AS/NZS ISO 18273.
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133
CONTENTS
A GUIDE TO INTERPRETING THE AUSTRALIAN
ANDNEW ZEALAND SPECIFICATION FOR REPAIR
AND HARDFACING CONSUMABLE
The AS/NZS 2576 Welding Consumable for Build-Up and Wear
Resistance is based on the Welding Technology Institute of
Australia (WTIA) Technical Note 4.
The standard classifes consumables by alloy type, deposit
hardness, welding process and consumable type. For complete
details of the consumable classifcations please refer to the latest
edition of AS/NZS 2576.
2ND DIGIT =
ALLOY TYPE
In combination with the frst
digit it indicates the specifc
type of alloy whithin a group.
23XX = Austenitic
chromium-carbide iron
2 3 6 0 - A4
1ST = ALLOY GROUP
1 = Steels
2 = Chromium white irons
3 = Tungsten carbide composites
4 = Cobolt alloys
5 = Nickel alloys
6 = Copper alloys
3RD & 4TH DIGIT = DEPOSIT HARDNESS
Indicates mean undiluted deposit hardness
prior to any heat treatment or work in service.
Hardness is expressed in Rockwell C (HRC) units.
ie. XX60 = 60-65 HRC
DEPOSITION PROCESS
The letter indicates the
welding process.
A = Manual Metal Arc Welding
B = Submerged Arc Welding and
Flux Cored Arc Welding
C = Gas Welding
5TH DIGIT = CONSUMABLE TYPE
A1 = Tubular electrode no alloy
contribution from the fux coating.
A4 = Low carbon steel core wire alloy
additive fux coating.
B1 = Tubular wire no alloy. contribution
from the fux coating.
B5 = Gas shielded tubular fux core wire.
B7 = Self shielded tubular fux core wire.
C1 = Filler Rod.
C3 = Powder.
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CONTENTS
CLASSIFICATION FOR SUBMERGED ARC WELDING
ELECTRODES AND FLUXES
The Australian Standard for electrodes and fuxes for SAW, AS
1858.1 (C and C-Mn Steels) published by Standards Australia
and its classifcation system has strong similarities with the ANSI /
AWS SAW specifcations, particularly in relation to electrode and
alloy weld metal designations and compositions. The following
provides a guide to the designations and layout of the classifcation
systems (shown in combined form) to acquaint the user with the
information provided by the classifcations. For full details of the
complete range of classifcation testing requirements, chemical,
mechanical, radiographic and other requirements of the standard,
consult AS 1858.1.
EXAMPLE: AS1858.1
EL12-FMM-W404 is a complete designation. It refers to a fux
and wire combination that will produce weld metal which in the
as-welded condition, will have a tensile strength no lower than
430 MPa and Charpy V-notch impact strength of a minimum of
35J at -40C when deposited with an EMK12 electrode under the
conditions called for in this specifcation.
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CONTENTS
CLASSIFICATION FOR SUBMERGED ARC WELDING
ELECTRODES AND FLUXES
E or EC XXX - F X X - W XX X X X HX
ELECTRODE AND WELD METAL
DESIGNATIONS AND COMPOSITIONS
Electrode C Mn Si
EL8
EL12
EM12K
0.10max
0.05-0.15
0.05-0.15
0.25/0.60
0.25/0.60
0.80/1.25
.0.07max
0.07max
0.10/0.35
Note: A small selection only of carbon
steel electrodes. For full list and details
refer tothe appropriate part of the
standard
FLUX
APPLICATION
S = Single Run
M = Multi Run
B = Basic Flux
G = General
Purpose
FLUX CONTRIBUTION TO WELD ANALYSIS
HYDROGEN
A suffx
indicating
hydrogen
controlled weld
metal may be
added when
max. H2 level
is established.
(AS 3752 - 1996)
H15 <15mL/100g
H10 <10mL/100g
H5 <5mL/100g
of deposits of
metal
ELECTRODE (SOLID)
ELECTRODE COMPOSITE (CORED)
WELD METAL HEAT TREATMENT
A+ Tested As Welded
P=Tested Post Weld
heat treated
WELD METAL STRENGTH DIGITS
The strength digits 40 and 50 in
part 1 of AS 1858 represent one-tenth
of the approximate min. tensile strength
in MPa of the tensile range. Each
strength level also has a min. Proof
Stress (0.2% Offset) and Elongation
requirements specifed by this standard.
IMPACT ENERGY NUMBER
0 = No impact required
1-5 = test temperature of +20C
to -60C in 20 intervals.
Energy Requirement
W40X = 35J
W50X = 40J
WXXX = 27J
FLUX
A = Alloys other than
Mn & Si and added to L,
M or H eg.LA, MA or HA
L = Low Mn & Si
M = Medium Mn & Si
H = High Mn & Si
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CONTENTS
WELD DEPOSITION
AND COSTING DATA
Weld costing systems differ throughout the world and between
companies in similar operations but with different methods of cost
accounting. Some variations in systems are due to variations
in methods of selling consumables. For example, MMAW
consumables may be sold by the number, length or mass of
the electrodes. However, all systems invariably rely on a basic
philosophy of determining the quantity (in kg.lb, m etc) of consumable
required to produce a given volume of joint. From this, the labour
time for joint completion, based on the deposition rate and duty
cycle estimates for the welding consumables/processes, welding
positions and workshop/site situations, in question, can be determined.
The costs of joint preparation and fnishing must also be considered,
and like the other factors mentioned can be substantially infuenced
at the design stage. The lowest welding costs are achieved when
full use is made of the high productivity welding processes and
when joints are designed specifcally for these processes.
Australia sells all major solid (and some gas) welding consumables
by mass (kg), and all requirements can be related back to the
mass of added weld metal required to produce a unit length of joint.
Most well equipped welding shops have a range of processes,
particularly MMAW, GMAW and SAW machines, and the following
approach to weld costing is based on a system which can integrate
the various methods and allow for substitution as desired.
THE WIA APPROACH TO WELD COSTS DETERMINATIONS
TO ASSIST YOU IN ESTIMATING WELDING COSTS WE
HAVE PUT TOGETHER THE FOLLOWING GUIDE IN FOUR
SECTIONS. A COMPREHENSIVE GUIDE TO USING
SECTIONS 1-4
The mass of weld metal in a length of joint is a product of its
volume (cross-sectional area x length) and its density. Most weld
joint cross-sections can be broken up into basic shapes as detailed
below and illustrated in Figure 10
137
CONTENTS
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RECTANGULAR
CROSS SECTIONS
Major area of the square,
vee and U joints and roof
gap components.
TABLE 1.0
TRIANGULAR
CROSS-SECTIONS
Major areas of vee and
bevel joints, fllet sections
TABLE 1.1
REINFORCMENT
CROSS-SECTIONS
1 Semi-elliptical shapes of
predictable or measurable
heights and widths
reinforcing the weld face.
TABLE 1.2
RADIUS
CROSS-SECTIONS
Part circle segments
associated with U and J
joints
TABLE 1.3
BACK GOUGED
CROSS-SECTIONS
The carbon arc electrode
selected Or gas nozzle)
determines the width, while
the rate of travel and angle
determines the depth of
gouge. Areas of predicable
contours are covered.
TABLE 1.4
FILLET WELD
SECTIONS
A range of fllet sizes and
shapes including convexity
and concavity allowances.
TABLE 1.5
138
CONTENTS
Figure 10
TABLES 1.0-1.5 of SECTION 1 are a convenient means of
determining the mass of weld metal per unit length of joint for
each of the simple joint cross-sections described. Simply look up
the appropriate dimensions of the shape in question, and the weld
metal mass, in kilograms per metre (kg/m), is calculated for you.
By referring to GUIDE 1, shown in the following pages, a practical
example is given illustrating the correct usage of TABLES 1.0-1.5
Where ready made tables are not available or greater accuracy
is required you can calculate the area. Given the length of the
required weld, the volume of weld metal can be calculated and
converted to the mass of weld metal, using an appropriate
density fgure. For example, 1 mm cross-sectional area of steel
weld metal by 1000 mm (1 metre) long has a mass of .00785
kg. Therefore, fnding the cross-sectional area, in mm, and
multiplying by .00785 will give the mass of weld metal per metre
of joint, in kg/m.
Side A
Side b
f
A h
A
h
B
f
B
d
r
d
2
T
1/2 L
WELD DEPOSITION
AND COSTING DATA
W= 2r
139
CONTENTS
A COMPREHENSIVE GUIDE TO USING SECTIONS 1-4 CONT.
Quantity of consumables data, tabled in section 2, allows
the quantity of consumable(s) required to weld a given joint,
to be calculated. Further to this, the DEPOSITION RATE and
Duty Cycle data of sections 3 & 4 enable realistic estimates
of actual welding speeds and times to be determined for
specifc consumables/welding processes, welding positions and
workshop/site situations. Detailed practical examples, illustrating
the use of information contained in Sections 2-4
are featured respectively in Guides 2-4.
BY FOLLOWING THE GUIDES THROUGH FROM 1-4 THE USER
IS GIVEN A STEP-BY-STEP METHOD FOR DETERMINING:
1. the mass of weld metal required per metre of joint
2. the quantity of consumable(s) required per metre of joint
3. the continuous (100% duty cycle) welding speed/time for one
metre of joint
4. a realistic estimate of the actual welding speed/time to
complete one metre of joint.
GUIDE 1 - DETERMINE MASS OF WELD PER METRE USING
TABLES 1.0 - 1.5 OF SECTION 1
(a) Fillet Welds
For fllet welds the user is directed to TABLE 1.5. Select the
desired leg length (L) with the likely degree of convexity (h) given
the electrode size/type used, the welding position and process
etc., and read off the mass of weld metal per metre of joint (kg/m).
For acute angle or obtuse angle fllets or fllets of unequal leg
length treat as for a butt weld and refer to (b).
(b) Butt Welds
For butt welds, frst sketch the joint cross-section under
consideration, breaking it down into fundamental shapes such
as rectangles, triangles and reinforcement and radius sections as
shown in fgure 10.
Dimension the shapes, from available information, by calculation or
by intelligent guessing. Using these dimensions, the mass of weld
metal per metre of joint can be arrived at for each shape segment
using the data from TABLES 1.0-1.4. From here, the total mass of
weld metal required per metre of joint can be simply calculated by
adding the fgures obtained for each shape segment.
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CONTENTS
PRACTICAL EXAMPLE 1
For the U-joint illustrated in FIGURE 10, assume the
following dimensions:
T (plate thickness) = 60 mm
= 10 (therefore, included angle is 20)
r (root radius) = 10 mm
d
(root face) = 8 mm
Side A Rectangular, Triangular and Radius Cross-Sections
With a root face (d
) of 8 mm and a root radius (r) of 10 mm, the

depth of the rectangular and triangular sections (d) will be, d =
T - (d
+ r) = 60 - 18 = 42 mm. The width of the rectangle (w) is of

course equal to 2r = 20 mm.
From table 1.0, the mass of weld metal per metre of joint required
for a rectangle of area, 20 x 42 mm = 840 mm2, is approximately
6.59 kg/m (A).
From table 1.1, two triangles with an included angle of 20 and a
depth of 42 mm will need a mass of weld metal per meter of joint
of approximately ....................................................2.50 kg/m (B).
From table 1.3, a semi-circular section of radius 10 mm will
require a mass of weld metal per metre of joint of approximately .
................................................................................1.23 kg/m (D).
GUIDE 1 CONT.
SIDE A REINFORCEMENT CROSS-SECTION
The reinforcement width of Side A (fA ) will be the addition of 2r
(20mm) and L (15mm, taken from TABLE 1.1) plus whatever
overlap onto the parent metal is considered desirable practice.
For this example, assume an average overlap of 3mm on each
side of the joint which gives fA = 6 + 20 + 15 = 41 mm. Also let us
assume a reinforcement height on Side A (hA ) of 3 mm.
From table 1.2, the mass of weld metal required per metre of joint
for the reinforcement section of Side A of f = 41 mm and h = 3 mm
is approximately ...................................................0.75 kg/m (C1).
WELD DEPOSITION
AND COSTING DATA
141
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SIDE B BACK GOUGED CROSS-SECTION
Here the user will be guided by such factors as, the welding
process used for the root pass, to determine resultant root
penetration, the fracture toughness requirements of the root and
established workshop practices, etc. to determine the extent of
back gouging required.
For this example, we will assume a carbon-arc gouge carried out
with a 10 mm carbon electrode to produce a groove 14 mm wide
and 10 mm deep. From TABLE 1.4, the mass of weld metal
required per metre of joint to fll a groove of these dimensions is
approximately .........................................................0.86kg/m (E).
Side B Reinforcement Cross-Section
With a gouge width of 14 mm (allow a little more for uneven
gouging) and estimating a 3 mm overlap onto each side of the
joint gives a reinforcement width for Side B (f8) of 21 mm.
From TABLE 1.2, the mass of weld metal required per metre of
joint for a reinforcement section of f = 21 mm and an assumed
height of h = 1.5 mm is approximately .................. 0.19 kg/m (C2).
Therefore, A + B + D + C1 + E + C2 gives the total mass of
weld metal required per metre of joint: 6.59 + 2.50 + 1.23 +
0.75 + 0.86 + 0.19 = 12.12 Kg/m
GUIDE 2 - DETERMINE QUANTITY OF CONSUMABLES
REQUIRED PER METRE USING TABLES 2.0 - 2.3 OF SECTION 2
Given the mass of weld metal required to Fill a metre of joint,
the next step is to determine the mass of consumable(s) initially
required. The weld metal yield achieved from welding with
a consumable electrode or fller wire largely depends on the
effciency of the welding process / consumable in question. This
effciency is infuenced by such inherent wastage factors as, weld
metal spatter, slag coverage and gas plume production. The
Quantity of consumables fgures listed in tables 2.0-2.3 are
for a weld metal yield of 1 kg and take account of these inherent
losses. An additional percentage (listed in the EXTRA FOR
WASTAGE column) is usually added to allow for typical shop
wastage such as stub ends & wire snips etc.
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CONTENTS
PRACTICAL EXAMPLE 1 CONTINUED
For the U-joint discussed in EXAMPLE 1 of GUIDE 1 let us
assume that 1.6 mm Austfl 71T with CO
shielding gas is used

for the single root pass weld on Side A and for welding the entire
back gouged section on Side B; and a SAW process using 4.0mm
wire is used for the remainder of the joint.
AUSTFIL 71T REQUIREMENTS (NOT INCLUDING
ALLOWANCE FOR SHOP WASTAGE)
Side A. Allow .25 kg of weld metal/metre of joint for the root pass
deposit (assuming that a single pass with a 1.6 mm Austfl 71T is
comparable in size to an 8 mm fllet weld).
Side B. From Guide 1, the mass of weld metal per metre of joint
for the back gouged cross-section (including reinforcement) is
1.05 kg/m. (0.86 +0.19)Therefore, the total weld metal required
from Austfl 71T is 1.05 + 0.25 = 1.30 kg/m.
From table 2.2 type A, 1.20 kg of Austfl 71T will produce 1 kg
of weld metal. Therefore, 1.20 x 1.30 = 1.56kg of Austfl 71T will
produce 1.30 kg of weld metal per metre of joint.
CO
Shielding Gas Consumption

To estimate CO
gas consumption let us assume, the 1.6mm

Austfl 71T is deposited at 350 Amps and 29 Volts, which will
produce a weld metal deposition rate of approx 5.4 kg/hr
(see table 3.2 part B of section 3).
GUIDE 2 CONT.
For a CO
fow rate of 12 L/min approximately 0.13m
(or .24kg)
of CO
gas will be consumed per kg of weld metal deposited (see

table 2.2). Therefore, 1.30 x 0.13 = 0.17 m3 (or .32 kg) of CO

will be used to deposit 1.30 kg of weld metal per metre of joint.
SAW FILLER METAL AND FLUX REQUIREMENTS (NOT
INCLUDING ALLOWANCE FOR SHOP WASTAGE)
The wire/fux submerged arc combination is required to produce
12.12 - 1.30 = 10.82 kg of weld metal per metre of joint. From
table 2.3 approximately 1.02 kg of wire will produce 1 kg of weld
metal. Therefore, 1.02 x 10.82 = 11.04 kg of wire will produce
10.82 kg of weld metal per metre of joint. Also from table 2.3
approximately 1.1 kg of fux is required to produce 1 kg of weld
metal. Therefore, 1.1 x 10.82 11.90 kg of fux will be consumed
to produce 10.82 kg of weld metal per metre of joint.In the
summary, the quantity of consumables required to complete
one metre of joint are:
WELD DEPOSITION
AND COSTING DATA
143
CONTENTS
1.6 kg of 1.6 mm Austfl 71T wire
0.2 m
(0.3 kg) of CO
shielding gas
11.0kg of wire
11.9 kg fux not including allowances for shop wastage.
GUIDE 3 - DETERMINE 100% DUTY CYCLE WELDING SPEED
TIME USING TABLES 3.0 - 3.6 of SECTION 3
From the Deposition Rate data in tables 3.0 - 3.6 of section 3
for the selected consumables and arc processes, the continuous
welding speed (in m/hr) and welding time (in hr/m) can be
determined. Where deposition conditions are substantially varied
for different sections of a joint - for example narrow root passes
versus wide weave capping passes, the welding speed should be
calculated separately rather than an average taken.
PRACTICAL EXAMPLE 1 CONTINUED
For the U-joint discussed in example 1 of guides 1 and 2 let us
assume the 1.6 mm Austfl 71T (used for the single root pass weld
on Side A and for welding the entire back gouged section on Side
B) is deposited at 350 amps and 29 volts under CO
shielding gas
with an electrode stickout of 25 mm. From table 3.2, part B, the
typical deposition rate is 5.4 kg/hr.
As calculated in guide 2, the wire requirements is 1.30 kg of weld
metal per metre of joint. Therefore the welding speed for Austfl
71T will be 5.4 1.30 = 4.15 metres of joint/hour or the welding
time will be 0.24 hours/metre of joint.
For welding the remainder of the joint with SAW process, assume
a welding current of 700 amps and voltage of 34 volts for the 4
mm wire nominated. From table 3.3 the typical deposition rate is
approximately 8.3 kg/hr.
As determined in guide 2, the wire/fux combination is required to
produce 10.82 kg of weld metal per metre of joint. Therefore, the
welding speed will be:
8.3 10.82 = 0.77 metres of joint/hour or the welding time will be
1.30 hours/metre of joint. 10.82From the calculated welding time
for continuous welding of the Austfl 71T /CO
and SAW process

combinations, the total welding time is .24 + 1.30 = 1.54 hours/
metre of joint.
In summary, given a duty cycle of 100%, (that is continuous,
uninterrupted, welding of the consumables detailed in this
example) one metre of joint will be completed in 1.54 hours.
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CONTENTS
GUIDE 4 DETERMINE REALISTIC ESTIMATE OF WELDING
SPEED/TIME USING THE DUTY CYCLE DATA OF SECTION 4
The continuous welding speeds and welding times, (That is for
a Duty Cycle of 100%) calculated in practical example 1 of
guide 3 serve as a starting point for determining realistic welding
speeds and welding times for joint completion.
As stated in section 4, Duty Cycle is a measure of the arc on
time as a percentage of the total time elapsed. The total elapsed
time must take into account all additional non-arc operations,
such as materials handling, weld deslagging, electrode changes
overs etc and personal allowances, as well as the total arc-on time.
In order to arrive at realistic welding speeds and times which
will approach the actual fgures achieved, it is important to use
duty cycle estimates which are realistic for the consumable/arc
process combinations and workshop/site in question.
The choice of a satisfactory duty cycle may be determined
by referring to past records for workshop or site projects
undertaken using similar welding consumables and arc
processes under similar working conditions. Since detailed
information of this nature is often unavailable, a suitable duty
cycle fgure may be arrived at by using published data and/or
by educated guessing.
section 4 entitled Duty Cycles details a range of achievable
duty cycles for the main arc welding processes used. The duty
cycles given under each heading are generally accepted as
maintainable by most reasonably equipped workshops or
welding sites.
To continue practical example 1 from guide 3, let us assume
from the information in parts (b) and (c) of SECTION 4;
a duty cycle of 30% for the FCAW process
a duty cycle of 40% for the SAW process
Therefore, a realistic estimate of the welding speed for Austfl
71T/CO
is 4.15 x .30 = 1.25 metres of joint/hour, and the welding

time is 0.80 hours/metre of joint; and a realistic estimate of the
welding speed for SAW process is 0.77 x .40 = 0.31 metres of
joint/hour, and the welding time is 3.25 hours/metre of joint.
WELD DEPOSITION
AND COSTING DATA
145
CONTENTS
FROM THE CALCULATED WELDING TIMES FOR THE FCAW
AND SAW COMBINATIONS THE TOTAL WELDING TIME TO
COMPLETE ONE METRE OF JOINT IS 0.80 + 3.25 = 4.05 HRS.
This welding time will be a good approximation of the actual time
to complete one metre of join given that the duty cycle estimates
used are realistic for the welding task involved.
PRACTICAL EXAMPLE 2
If, for the joint described in example 1, the initial two passes on
Side A and all of Side B is welded with MMAW electrodes, Austarc
77 and Austarc 24 -instead of Austarc 71T; and the remainder
of the joint is welded with SAW process, the following variations
could take place.
Side A. The initial two passes with 4 mm Austarc 18TC will deposit
2 x .14 = .28 kg of weld metal per metre of joint (assuming, a
single pass with 4 mm Austarc 18TC is comparable to a 5 mm
fllet, see section 1, Table1.5). The remainder of Side A is to be
welded with SAW process.
Side. The frst pass welded with 4 mm Austarc 18TC will deposit
.14 kg of weld metal per metre of joint. The remainder of Side B is
to be complete with 5 mm Austarc 24.
GUIDE 4 CONT.
4 MM AUSTARC 18TC REQUIREMENT
The total mass of weld metal required from 4 mm Austarc 18TC is
.28 + .14 = .42 kg per metre of joint.
At a typical current setting of 170 amps, the deposition rate (at
100% duty cycle) is 170 x .01 = 1.70 kg/hr (see section 3 table
3.0) Therefore, the continuous welding time to deposit .45 kg of
weld metal with 4 mm Austarc 18TC is.
.42 = 0.25 hours/metre of joint
170
Assuming a duty cycle of 25% (see section 4), a realistic estimate
of the actual welding time is
.25
= 1,00 hours/metre of joint
.25
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146
CONTENTS
5 MM AUSTARC 24 REQUIREMENT
The remainder of Side B requires 1.05 - 0.14 = 0.91 kg of weld
metal per metre of joint, deposited with 5 mm Austarc 24.
At a typical current setting of 300 amps, the deposition rate (at
100% duty cycle) is 300 x 0.135 =
4.05 kg/hr (see section 3, table 3.0) Therefore, the continuous
welding time to deposit 0.92 kg of weld metal with 5 mm
Austarc 24 is
0.91
= 0.22 hours/metre of joint

4.05
Assuming a duty cycle of 30% (see section 4), a realistic
estimate of the actual welding time is
.22

.30
SAW CONSUMABLE
The remainder of Side A requires 11.07 - .28 = 10.79 kg of weld
metal per metre of joint.
A typical current and voltage setting of 700 amps and 34 volts,
for the 5 mm SAW wire nominated will produce a
typical deposition rate (at 100% duty cycle) of 8.3 kg/hr
(see section 3, table 3.3)
Therefore, the continuous welding time to deposit 10.72 kg
of weld metal with 5 mm wire is
10.79

8.3
Assuming a duty cycle of 40% (see SECTION 4), a realistic
estimate of the actual time is
1.30

.40
For Example 2, The Total Welding Time To Complete
One Metre Of Joint May Be Summarised As Follows:
4mm Austarc 18TC (at 25% duty cycle) - 1.00 hrs/metre of joint
5mm Austarc 24 (at 30% duty cycle) - 0.73 hrs/metre of joint
5mm wire/fux combination (at 40% duty cycle) - 3.25 hrs/metre of joint
Estimate of actual welding time to complete joint -
4.98 hrs/metre of joint
WELD DEPOSITION
AND COSTING DATA
147
CONTENTS
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RECTANGULAR WELD
CROSS-SECTIONS TABLE
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d
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dd
d
w
148
CONTENTS
MASS OF STEEL WELD METAL PER METRE OF JOINT (kg/m)
Depth
d
(mm)
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
6 3.5 008 6.0 0.14 2.1 005 3.2 0.08
8 4.6 0.14 8.0 0.25 2.8 0.09 4.3 0.14
10 5.8 0.23 10.0 0.39 3.5 0.14 5.4 0.21
12 6.9 0.32 12.0 0.57 4.2 0.20 6.4 0.30
14 8.1 0.45 14.0 0.77 4.9 0.27 7.5 0.41
16 9.2 0.58 16.0 1.00 5.6 0.35 8.6 0.54
20 11.5 0.90 20.0 1.57 7.1 0056 10.7 0.84
22 12.7 1.10 22.0 1.90 7.8 0.67 11.8 1.02
24 13.9 1.31 24.0 2.26 8.5 0.80 12.9 1.22
26 15.0 1.53 26.0 2.65 9.5 0.94 13.9 1.42
28 16.2 1.78 28.0 3.08 9.9 1.09 15.0 1.65
30 17.3 2.04 30.0 3.53 10.6 1.25 16.1 1.90
35 20.2 2.77 35.0 4.81 12.3 1.69 18.8 2.58
40 23.1 3.63 40.0 6.28 14.1 2.21 21.4 3.36
45 26.0 4.59 45.0 7.95 15.9 2.81 24.1 4.26
50 28.9 5.67 50.0 9.81 17.6 3.45 26.8 5.26
55 31.8 6.86 55.0 11.87 9.4 4.19 29.5 6.37
60 34.6 8.15 60.0 14.13 21.2 5.99 32.2 7.58
70 40.4 11.10 70.0 19.23 24.7 6.79 37.5 10.30
75 43.3 12.75 75.0 22.08 26.4 7.77 40.2 11.83
80 46.2 14.51 80.0 25.12 28.2 8.85 42.9 13.47
TABLE 1.1 TRIANGULAR WELD CROSS-SECTIONS
MASS OF WELD
METAL IN JOINT
30
45 20
L L L
d
d
d
30
L
d
SECTION SHAPES AND ANGLES
149
CONTENTS
Depth
d
(mm)
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
6 3.5 008 6.0 0.14 2.1 005 3.2 0.08
8 4.6 0.14 8.0 0.25 2.8 0.09 4.3 0.14
10 5.8 0.23 10.0 0.39 3.5 0.14 5.4 0.21
12 6.9 0.32 12.0 0.57 4.2 0.20 6.4 0.30
14 8.1 0.45 14.0 0.77 4.9 0.27 7.5 0.41
16 9.2 0.58 16.0 1.00 5.6 0.35 8.6 0.54
20 11.5 0.90 20.0 1.57 7.1 0056 10.7 0.84
22 12.7 1.10 22.0 1.90 7.8 0.67 11.8 1.02
24 13.9 1.31 24.0 2.26 8.5 0.80 12.9 1.22
26 15.0 1.53 26.0 2.65 9.5 0.94 13.9 1.42
28 16.2 1.78 28.0 3.08 9.9 1.09 15.0 1.65
30 17.3 2.04 30.0 3.53 10.6 1.25 16.1 1.90
35 20.2 2.77 35.0 4.81 12.3 1.69 18.8 2.58
40 23.1 3.63 40.0 6.28 14.1 2.21 21.4 3.36
45 26.0 4.59 45.0 7.95 15.9 2.81 24.1 4.26
50 28.9 5.67 50.0 9.81 17.6 3.45 26.8 5.26
55 31.8 6.86 55.0 11.87 9.4 4.19 29.5 6.37
60 34.6 8.15 60.0 14.13 21.2 5.99 32.2 7.58
70 40.4 11.10 70.0 19.23 24.7 6.79 37.5 10.30
75 43.3 12.75 75.0 22.08 26.4 7.77 40.2 11.83
80 46.2 14.51 80.0 25.12 28.2 8.85 42.9 13.47
Depth
d
(mm)
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
Width
L
(mm)
kg/m
6 5.6 0.13 6.9 0.16 8.4 0.20 12.0 0.28
7.5 7.5 0.24 9.2 0.29 11.2 0.35 16.0 0.50
10 9.3 0.37 11.5 0.45 14.0 0.55 20.0 0.79
12 11.2 0.53 13.9 0.65 16.8 0.79 24.0 1.13
14 13.1 0.72 16.2 0.89 19.6 1.08 28.0 1.54
16 14.9 0.94 18.5 1.16 22.4 1.41 32.0 2.01
20 18.7 1.47 23.1 1.81 28.0 2.20 40.0 3.14
22 20.5 1.77 25.4 2.19 30.8 2.66 44.0 3.80
24 22.4 2.11 27.7 2.61 33.6 3.17 48.0 5.42
26 24.2 2.47 30.0 3.06 36.4 3.71 52.0 5.31
28 26.1 2.87 32.3 3.55 39.2 4.31 56.0 6.15
30 28.0 3.30 34.6 4.07 42.0 4.95 60.0 7.07
35 32.6 4.48 40.4 5.55 49.0 6.73 70.0 9.62
40 37.3 5.86 46.2 7.25 56.0 8.79 80.0 12.56
45 42.0 7.42 52.0 9.18 63.0 11.13 90.0 15.90
50 46.6 9.15 57.7 11.32 70.0 13.74 100.0 19.63
55 51.3 11.07 63.5 13.71 77.0 16.62 110.0 23.75
60 56.0 13.19 69.3 16.32 84.0 19.78 120.0 28.26
70 65.3 17.94 80.8 22.20 98.0 26.93 140.0 38.47
75 69.9 20.58 86.6 25.49 105.0 30.91 150.0 44.16
80 74.6 23.42 92.4 29.01 112.0 35.7 160.0 50.24
TABLE 1.1 TRIANGULAR WELD CROSS-SECTIONS CONT.
SECTION SHAPES AND ANGLES
70
L
d
90
L
d
60
L
50
L
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150
CONTENTS
Depth,
d
(mm)
REINFORCEMENT HEIGHT, h.
h=1.0mm h=1.5mm h=3.0mm h=4.5mm h=6.0mm
6 0.04 0.06
8 0.05 0.07
10 0.06 0.09 0.18 0.28
12 0.07 0.11 0.22 0.33
14 0.09 0.13 0.26 0.39
16 0.10 0.15 0.30 0.44
20 0.12 0.18 0.37 0.55 0.74
22 0.14 0.20 0.41 0.61 0.81
24 0.15 0.22 0.44 0.67 0.89
26 0.16 0.24 0.48 0.72 0.96
28 0.17 0.26 0.52 0.78 1.04
30 0.18 0.28 0.55 0.83 1.11
35 0.22 0.32 0.65 0.97 1.29
40 0.25 0.37 0.74 1.11 1.48
45 0.28 0.42 0.83 1.25 1.66
50 0.31 0.46 0.92 1.39 1.85
Note. For face widths in excess of 50 mm, estimate average height of
reinforcement and calculate as for a rectangle, referring to table 1.0
TABLE 1.2 WELD REINFORCEMENT CROSS-SECTIONS
MASS OF WELD
METAL IN JOINT
F
h
151
CONTENTS
Depth,
d
(mm)
REINFORCEMENT HEIGHT, h.
h=1.0mm h=1.5mm h=3.0mm h=4.5mm h=6.0mm
6 0.04 0.06
8 0.05 0.07
10 0.06 0.09 0.18 0.28
12 0.07 0.11 0.22 0.33
14 0.09 0.13 0.26 0.39
16 0.10 0.15 0.30 0.44
20 0.12 0.18 0.37 0.55 0.74
22 0.14 0.20 0.41 0.61 0.81
24 0.15 0.22 0.44 0.67 0.89
26 0.16 0.24 0.48 0.72 0.96
28 0.17 0.26 0.52 0.78 1.04
30 0.18 0.28 0.55 0.83 1.11
35 0.22 0.32 0.65 0.97 1.29
40 0.25 0.37 0.74 1.11 1.48
45 0.28 0.42 0.83 1.25 1.66
50 0.31 0.46 0.92 1.39 1.85
Radius
r
(mm)
MASS OF WELD METAL PER
METRE OF JOINT (kg/m)
U J
3 0.11 0.06
4 0.20 0.10
5 0.31 0.15
6 0.44 0.22
7 0.60 0.30
8 0.79 0.39
9 1.00 0.50
10 1.23 0.62
11 1.49 0.75
12 1.18 0.89
13 2.08 1.04
14 2.42 1.21
15 2.77 1.39
Depth
r
(mm)
Width
(mm)
Area
(mm)
MASS OF
WELD
METLEL PER
METRE OF
JOINT (kg/m)
1.5 6 7.07 0.06
2.5 8 15.71 0.12
3.5 7 19.24 0.15
4 12 37.70 0.30
5 10 37.27 0.31
7 12 65.97 0.52
8 19 119.38 0.94
10 14 109.96 0.96
10 22 172.79 1.36
12 20 188.50 1.48
15 30 353.43 2.77
Note. Note: Appropriate reinforcement additions, selected from
table 1.2, will generally be required to be added to the above fgures.
TABLE 1.3 RADIUS WELD CROSS-SECTIONS
MASS OF WELD
METAL IN JOINT
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1/2 width
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152
CONTENTS
WELD SIZE
Cross- sectional
Area (mm)
MASS OF WELD METAL PER METRE (kg/m)
Leg Length, L
Throat Thickness
T (mm)
Flat and Convex Welds Convex Welds
(mm) (inch)
h=0
(There.)
h=1.0mm h=1.5mm h=2.5mm
Throat
Thickness
T (mm)
Typical
Concave
Weld
3.2 1/8 2.3 5.1 .04 .07 .08 - 2.3 0.05
3.5 2.5 6.1 .05 .08 .10 - 2.5 0.06
4.0 5/32 2.8 8.0 . 06 .09 .11 - 2.8 0.07
4.8 3/16 3.4 11.5 .09 .13 .15 - 3.4 0.10
5.0 3.5 12.5 .10 .14 .17 - 3.5 0.11
5.6 7/32 4.0 15.7 .12 .17 .19 - 4.0 0.13
6.0 4.2 18.0 .14 .19 .22 - 4.2 0.15
6.4 1/4 4.5 20.5 .16 .22 .24 - 4.5 0.17
7.0 4.9 24.5 .19 .25 .28 - 4.9 0.21
8.0 ~5/16 5.7 32.0 .25 .32 .35 - 5.7 0.27
9.5 3/8 6.7 45.1 .36 .44 .48 .57 7.7 0.39
10.0 7.1 65.0 .39 .48 .52 .61 7.1 0.42
12.7 7.1 50.0 .63 .74 .80 .91 9.0 0.68
15.9 5/8 11.2 126.4 .99 1.13 1.20 1.34 11.2 1.06
19.0 ~3/4 13.4 180.5 1.42 1.59 1.67 1.84 13.4 1.52
22.2 7/8 15.7 246.4 1.93 2.13 2.23 2.42 15.7 20.6
24.4 1.0 18.0 322.6 2.53 2.75 2.86 3.08 18.0 2.70
TABLE 1.5 FILLET WELDS
The table shows the mass of steel weld metal per metre of
joint (kg/m) for fllet welds of varying degrees of convexity and a
typical concave profle. The fgures are based on actual leg length
being maintained. Note that the leg lengths shown are
not applicable to the concave welds which are designated in
this table by throat thickness.
153
CONTENTS
WELD SIZE
Cross- sectional
Area (mm)
MASS OF WELD METAL PER METRE (kg/m)
Leg Length, L
Throat Thickness
T (mm)
Flat and Convex Welds Convex Welds
(mm) (inch)
h=0
(There.)
h=1.0mm h=1.5mm h=2.5mm
Throat
Thickness
T (mm)
Typical
Concave
Weld
3.2 1/8 2.3 5.1 .04 .07 .08 - 2.3 0.05
3.5 2.5 6.1 .05 .08 .10 - 2.5 0.06
4.0 5/32 2.8 8.0 . 06 .09 .11 - 2.8 0.07
4.8 3/16 3.4 11.5 .09 .13 .15 - 3.4 0.10
5.0 3.5 12.5 .10 .14 .17 - 3.5 0.11
5.6 7/32 4.0 15.7 .12 .17 .19 - 4.0 0.13
6.0 4.2 18.0 .14 .19 .22 - 4.2 0.15
6.4 1/4 4.5 20.5 .16 .22 .24 - 4.5 0.17
7.0 4.9 24.5 .19 .25 .28 - 4.9 0.21
8.0 ~5/16 5.7 32.0 .25 .32 .35 - 5.7 0.27
9.5 3/8 6.7 45.1 .36 .44 .48 .57 7.7 0.39
10.0 7.1 65.0 .39 .48 .52 .61 7.1 0.42
12.7 7.1 50.0 .63 .74 .80 .91 9.0 0.68
15.9 5/8 11.2 126.4 .99 1.13 1.20 1.34 11.2 1.06
19.0 ~3/4 13.4 180.5 1.42 1.59 1.67 1.84 13.4 1.52
22.2 7/8 15.7 246.4 1.93 2.13 2.23 2.42 15.7 20.6
24.4 1.0 18.0 322.6 2.53 2.75 2.86 3.08 18.0 2.70
h
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154
CONTENTS
CONSUMABLES TYPE
ELECTRODE
LENGTH
(mm)
QUANTITY OF
CONSUMABLES
EXTRA
FOR
WASTAGE
50mm
Stub
Length
75mm
Stub
Length
High Effciency (150%),
Iron Type Electrodes
EXX24, 27 & 28 to
AS/NZS 4855
450 1.60 1.66 10%
380 1.63 1.75 10%
Conventional, Low Iron
Powder or Hydrogen
Controlled Electrodes
EXX12, 13, 14, 16 &18
Types to AS/NZS 4855
450 1.63 1.73 10%
380 1.66 1.73 10%
Cellulose Type
Electrodes
(EXX10 & 11 Types
to AS/NZS 4855)
380 1.73 1.87 10%
CONSUMABLES TYPE,
CONDITIONS ECT.
QUANTITY
OF
CONSUMABLE
EXTRA
FOR
WASTAGE
Mild and Low Alloy Steel Welding Wire 1.02 2%
Flux Consumption - For any given wire
size under the following conditions
Low Voltage, Normal Amperage 0.8 kg 15%
Low Amperage, Normal Voltage 1.6 kg 15%
Normal Voltage, Normal Amperage 1.1 kg 15%
High Voltage, Normal Amerpage 1.6 kg 15%
Hight Amperage, Normal Voltage 0.8 kg 15%
Note. For Aluminium weld metal divide the steel weld metal mass per metre by 2.9
The QUANTITY OF CONSUMABLE
fgures listed in TABLES 2.0 - 2.3 are for a weld metal production
of 1kg and to take into account inherent wastage losses such as
weld metal spatter, slag coverage, and gas plume production.
An additional percentage (listed in the EXTRA FOR WASTAGE
column) is usually added to allow for typical shop wastage
such as stub ends and wire snips etc.To obtain the quantity of
consumable required to produce 1kg of weld metal read directly
from tables 2.0 - 2.3 for the appropriate consumable, shielding
gas, arc transfer mode etc.
QUANTITY OF
CONSUMABLES REQUIRED
TABLE 2.0 MANUAL METAL-ARC WELDING (MMAW)
TABLE 2.3 SUBMERGED-ARC WELDING (SAW)
155
CONTENTS
CONSUMABLES TYPE, SHIELDING
GAS, ARC TRANSFER MODE ECT.
QUANTITY
OF
CONSUMABLE
EXTRA
FOR
WASTAGE
TYPE A MILD ALLOY STEEL WELDING WIRES
(AUSTMIG ES6, ESD2 ECT)
USED WITH
(i) CO

SHIELDING GAS
Short Arc Transfer (95%)
1.05 kg 2%
Globular Transfer (90%) 1.11 kg 2 %
Globular Free Flight Transfer (93%) 1.08 kg 2%
(ii) Ar + 15 - 25% CO

SHIELDING GAS
Short Arc Transfer (97%)
1.03 kg 2%
Globular Transfer (94%) 1.06 kg 2%
Streaming Spray Transfer (96%) 1.04 kg 2%
(iii) Pulsed Arc Transfer (:Syncro-Pulse
CDT) and Programmed Shielding Gas
(98%)
1.02 kg
TYPE B STAINLESS STEEL WELDING WIRES
(eg. AUSTMIG 308LSI, 316SI ect):
USED WITH Ar or Ar/He Based Shielding
Gases and all Arc Transfer Modes,
including Pulsed Arc Transfer (98%)
1.02 kg
TYPICAL
CONDITIONS
DEPOSITION
RATE OF:
CONSUMPTION PER
KG OF WELD METAL
EXTRA
FOR
WASTAGE
Short Arc Transfer or
Pulsed Arc Transfer
with a Typical Gas
Flow rate of 15L/min
1.0 kg/hr;
.90m

(1.68kg of
CO
+)
10%
2.8 kg/hr .32m

(.60kg of CO
+) 10%
Globular, FreeFlight
or Streaming
Spray Transfer with
a typical Gas Flow
Rate of 20L/min
3.0 kg/hr
.40m

(.75kg of
CO
+)
10%
7.0 kg/hr .17m

(32kg of CO
+) 10%
TABLE 2.1 GAS METAL-ARC WELDING (GMAW)
AND PULSED ARC WELDING
SHIELDING GAS CONSUMPTION FOR MILD, LOW ALLOY
AND STAINLESS STEEL WIRES
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(%) Typical Electrode Effciency for wire type, shielding gas and transfer mode
Indicated. + Where appropriate, the mass of CO
shielding gas required.NB. 1m

of CO
at 15.6C and 1 atmosphere has a mass of 1.87 kg. 1m
= 1000 Litres.
156
CONTENTS
CONSUMABLES TYPE, SHIELDING GAS,
ARC TRANSFER MODE ECT.
QUANTITY OF
CONSUMABLE
EXTRA
FOR
WASTAGE
TYPE D ALUMINIUM WELDING WIRES
(eg. AUSTMIG 5356, 4043, 5183 etc.)
Spray Arc Transfer (95%) 1.05 kg 1%
Pulsed Arc Transfer (Syncro-Pulse CDT) (98%) 1.02 kg 1%
TYPICAL CONDITIONS
DEPOSITION
RATE OF:
QUANTITY OF
CONSUMABLE
EXTRA
FOR
WASTAGE
Spray Arc Transfer with a
Inert Gas Flow Rate
1.0kg/hr 1.68m3 10%
of 28L/min 2.0kg/hr 0.84m3 10%
Pulsed Arc Transfer with a
Inert Gas Flow Rate
0.5kg/hr 2.16m3 10%
of 18L/min 2.0kg/hr 0.54m3 10%
(%) Typical Electrode Effciency for arc transfer mode Indicated.
TABLE 2.1 GAS METAL-ARC WELDING (GMAW) AND
PULSED ARC WELDING
SHIELDING GAS CONSUMPTION FOR FOR ALUMINIUM WIRES:
QUANTITY OF
CONSUMABLES REQUIRED
157
CONTENTS
CONSUMABLES TYPE, TYPICAL
DEPOSITION EFFICIENCY ECT.
QUANTITY OF
CONSUMABLE
EXTRA
FOR
WASTAGE
TYPE A GAS SHIELDED, DOWNHAND
AND POSITIONAL, DCEP WIRES
OF 83% EFFICIENCY:
(E70T-1, E71T-5 TYPES TO AWS A5.20)
1.20 kg 2%
TYPE B SELF SHIELDED, DOWNHAND
DCEP WIRES OF 83% EFFICIENCY:
1.20 kg 2%
TYPE C GAS SHIELDED,
DOWNHAND METAL CORED WIRES
OF 95% EFFICIENCY:
1.05 kg 2%
TYPE D SELF SHIELDED, POSITIONAL
DCEN WIRES OF 75% EFFICIENCY:
1.20 kg 2%
Assuming a gas fow
rate of 12 L/minfor a
weld deposition rate of:
CONSUMPTION PER
KG OF WELD METAL
EXTRA
FOR
WASTAGE
2 kg/hr; .36m
(.67kg of CO
*) 10%
4 kg/hr; .32m
(.18kg of CO
*) 10%
6 kg/hr; .40m
(.12kg of CO
*) 10%
8 kg/hr; .17m
(.09kg of CO
*) 10%
* Where appropriate, the mass of CO
shielding gas required.

NB. 1 m3 of CO
at 15.6C and 1 atmosphere has a mass of 1.87 kg.

1 m3 = 1000 Litres.
TABLE 2.2 FLUX CORED ARC WELDING (FCAW)
TABLE 2.2 FLUX CORED ARC WELDING (FCAW)
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158
CONTENTS
DEPOSITION RATES
ELECTRODE
TYPE,
CLALSSIFICATION
TO AS/NZS 4855
WIA
ELECT-
RODES
TYPICAL
(F)

FACTOR
kg/amp/
hr
DEPOSITION F X A = kg/hr
TYPICAL CURRENT, A( )
5mm 4mm 3.2mm
E4110/11 11 .009 1.7(190) 1.4(150) 1.0(110)
E4112/13
12P,
13S
.008 1.8(220) 1.4(170) 1.0(130)
E4814 - .01 2.4(240) 1.9(190) 1.4(135)
E4824 24 .0135 4.1(300) 2.7(200) 2.0(150)
E4127 .0135 4.1(300) 2.8(210) 2.0(150)
E4816 16TC .009 2.0(220) 1.5(170) 1.2(130)
E4818 / E4846
18TC,
77
.01 2.0(200) 1.6(160) 1.2(115)
The factors (F) are typical for those low carbon steel electrodes, as classifed
to AS/NZS 4855 in popular use throughout Australia. Multiplying the FACTOR
(F) by the CURRENT (A) selected for the electrode size (within its normal
current range) will provide typical deposition rates (kg/hr) at 100% duty cycle.
TABLES 3.0-3.5 provide a comprehensive range of typical
deposition rates for the continuous operation of various arc
welding consumables and arc processes. The tables are
designed as an easy-to-read guide to show typical deposition
rates achievable tor the electrode/wire types, sizes, welding
parameters and shielding gases shown. The tables also give
useful information on suitable welding parameters such as
welding current, voltage and modes of operation. It should be
emphasised that the deposition rates tabulated are for continuous
operation (100% duty cycle) of the consumable/arc process in
question. Refer to SECTION 4 for further information on typical
duty cycle estimates for the welding task involved. The typical
deposition rates given for each current setting may vary with
changes in arc voltage, electrode stickout and shielding gas
composition - refer to the information given below each Table.
For accurate deposition rate calculations for continuous wires,
measure wire feed speed (in m/min) during welding and use the
appropriate Mass/Length fgures from table 3.6 and Quantity
of Consumables data from tables 2.1-2.3.
TABLE 3.0 TYPICAL DEPOSITION RATES USING MMAW
159
CONTENTS
TABLE 3.1A TYPICAL DEPOSITION RATES USING GMAW
WITH LOW CARBON AND LOW ALLOY STEEL WIRES
(EG AUSTMIG ES6, ESD2 OR SIMILAR WIRES)
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WIRE
SIZE
(mm)
WELDING
CURRENT
(AMPS)
ARC
VOLTAGE
(VOLTS)
WIRE FEED
SPEED (M/
MIN)
DEPOSITION
RATE (kg/hr)
0.8 60+ 16+ 3.3 0.7
0.8 80+ 17+ 4.4 1.0
0.8 100+ 18.5+ 5.9 1.3
0.8 120+ 20+ 7.0 1.6
0.8 140+ 20+ 9.9 2.2
0.8 160+ 22+ 12.4 2.8
0.8 180 30 14.3 3.2
0.9 70+ 15+ 3.7 1.1
0.9 100+ 19+ 6.0 1.7
0.9 120+ 19+ 6.9 2.0
0.9 150+ 20+ 8.7 2.5
0.9 180+ 21+ 11.5 3.3
0.9 180 29 12.0 3.4
0.9 200 31 14.0 4.0
1.0 90+ 19+ 3.3 1.2
1.0 100+ 19+ 3.6 1.3
1.0 150+ 20+ 5.6 2.0
1.0 100+ 20+ 7.0 2.5
1.0 220 28 14.6 5.2
1.0 250 32 15.7 5.6
1.0 280 34 16.8 6.0
1.2 120+ 18+ 2.7 1.4
1.2 150+ 18+ 3.5 1.8
1.2 170+ 19+ 3.9 2.0
1.2 220 30 6.2 3.2
1.2 250 32 9.1 4.7
1.2 310 34 11.3 5.8
1.2 340 36 12.9 6.6
1.6 140+ 19+ 1.7 1.6
1.6 200+ 19+ 1.7 1.6
1.6 250+ 21+ 3.1 2.8
1.6 300 30 4.9 4.5
1.6 350 34 6.2 6.7
1.6 400 34 7.5 6.8
+ Short arc transfer conditions. Note: Deposition rate data determined using:
DC+ (reverse polarity) with a conventional constant power source.
Ar - 16/18% CO2 shielding gas
An electrode stickout length at 8-10 mm for short arc transfer conditions
and 15 mm for spray arc transfer conditions.
Deposition effciency at 96% for both short arc transfer & spray arc transtor conditions
160
CONTENTS
TABLES 3.1B TYPICAL DEPOSITION RATES USING PULSED
ARC WELDING WITH LOW CARBON AND LOW ALLOY
STEEL WIRES (EG AUSTMIG ES6)
DEPOSITION RATES
WIRE
SIZE
(mm)
WELDING
CURRENT
(AMPS)
ARC
VOLTAGE
(VOLTS)
WIRE FEED
SPEED
(M/MIN)
DEPOSITION
RATE (kg/hr)
0.8 35 17.0 2.0 0.5
0.8 70 20.0 5.3 1.2
0.8 105 23.0 8.6 2.9
0.8 140 25.0 11.9 2.7
0.8 175 28.0 15.2 3.5
0.9 40 18.0 2.5 0.7
0.9 45 17.0 1.9 0.7
0.9 90 21.0 6.1 1.8
0.9 135 24.0 9.3 2.7
0.9 180 27.0 12.5 3.7
0.9 230 30.0 16.0 4.7
1.0 110 21.0 5.3 1.9
1.0 170 24.0 8.4 3.1
1.0 230 28.0 11.5 4.2
1.0 290 31.0 14.6 5.3
1.2 40 19.0 1.5 0.8
1.2 100 21.5 3.5 1.8
1.2 160 24.0 5.5 2.9
1.2 220 26.5 7.4 3.9
1.2 280 29.0 94 4.9
1.2 350 32.0 11.7 6.1
1.6 70 20.0 1.3 1.2
1.6 165 24.0 2.8 2.6
1.6 260 28.0 4.4 4.1
1.6 355 31.0 5.9 5.5
1.6 450 35.0 7.5 7.0
WIRE
SIZE
(mm)
DEPOSITION RATE (kg/hr) - WELDING CURRENT (AMPS)
300 400 500 600 700 800 900
2.0 3.1 4.8 - - - - -
2.4 2.9 4.1 5.5 7.5 - - -
3.2 2.6 3.9 5.3 6.8 8.7 10.1 -
4.0 - 3.6 5.1 6.7 8.3 10.0 11.9
4.8 - - - 5.0 7.4 8.9 10.4
Deposition rate data achieved using DC+ (reverse polarity) with, normal voltage
settings for the wire sizes listed. An electrode stickout of 25mm is used with all wire
sizes & current settings. Note: Deposition rates may be increased by 30-50% using DC-
(Straight Polarity) & approximately 15-25% using AC. The use of an electrode stickout
longer than 25mm with the same welding current increases deposition rate signifcantly.
Note: Deposition rate data obtained using: Ar + 16-18% CO2 shielding gas
A deposition effciency of 98% for pulsed arc transfer
TABLE 3.3 TYPICAL DEPOSITION RATES USING SUBMERGED-ARC
WELDING (SAW) WITH LOW CARBON AND LOW ALLOY STEEL WIRES
161
CONTENTS
TABLE 3.2A TYPICAL DEPOSITION RATES USING FCAW
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WIRE
SIZE
(mm)
WELDING
CURRENT
(AMPS)
ARC
VOLTAGE
(VOLTS)
WIRE FEED
SPEED
(M/MIN)
DEPOSITION
RATE (kg/hr)
PART A. T1 TYPE OF CORED WIRE
1.2 130 23 3.4 1.4
1.2 150 24 5.3 2.2
1.2 200 26 7.4 3.3
1.2 250 28 9.8 4.5
1.6 200 26 3.7 2.4
1.6 250 28 5.1 3.4
1.6 300 30 6.7 4.4
1.6 350 32 8.2 5.4
1.6 400 34 10.8 7.1
1.6 425 36 11.5 7.6
2.4 300 27 2.4 3.4
2.4 350 28 3.0 4.3
2.4 400 32 3.7 5.2
2.4 450 32 4.3 6.1
2.4 500 34 5.0 7.1
2.4 525 35 5.5 7.8
PART B. T5 TYPE OF CORED WIRE
1.2 130 22 3.4 1.4
1.2 150 23 5.3 2.2
1.2 200 24 7.4 3.3
1.2 250 26 9.8 4.5
1.6 200 25 3.7 2.4
1.6 250 27 5.1 3.4
1.6 300 28 6.7 4.4
1.6 350 29 8.2 5.4
1.6 375 30 9.4 6.1
2.4 300 25 2.4 3.4
2.4 350 26 3.0 4.3
2.4 400 28 3.7 5.2
2.4 450 29 4.3 6.1
2.4 475 30 4.7 6.6
Note. Deposition rate data determined using:
DC+ (reverse polarity) with a conventional Constant Potential power source
Welding grade CO
shielding gas
An electrode stickout length of, 15mm for 1.2mm, 25mm for 1.6mm
& 2.4mm wire sizes
A deposition effciency of 84% for globular transfer
Voltage fgures are typical machine meter readings-actual arc voltage will
be 1-3 volts lower than meter reading due to voltage drop across welding leads.
Reduce arc voltage by 2-3 volts when using mixed gas.
Deposition rate data achieved using DC+ (reverse polarity) with, normal voltage
settings for the wire sizes listed. An electrode stickout of 25mm is used with all wire
sizes & current settings. Note: Deposition rates may be increased by 30-50% using DC-
(Straight Polarity) & approximately 15-25% using AC. The use of an electrode stickout
longer than 25mm with the same welding current increases deposition rate signifcantly.
162
CONTENTS
TABLES 3.4A TYPICAL DEPOSITION RATES USING GMAW
WITH 300 SERIES STAINLESS STEEL SOLID WIRES
TABLE 3.4B TYPICAL DEPOSITION RATES USING PULSED
ARC WELDING WITH 300 SERIES STAINLESS STEEL
SOLID WIRES
DEPOSITION RATES
WIRE
SIZE
(mm)
WELDING
CURRENT
(AMPS)
ARC
VOLTAGE
(VOLTS)
WIRE FEED
SPEED
(m/min)
DEPOSITION
RATE (kg/hr)
0.9 80+ 17+ 4.2 .3
0.9 100+ 18+ 5.1 1.5
0.9 150 20 8.4 2.5
0.9 200 23 12.5 3.7
1.2 125+ 18+ 3.1 1.6
1.2 200 20 5.9 3.1
1.2 250 27 8.1 4.3
1.2 300 29 10.9 5.8
WIRE
SIZE
(mm)
WELDING
CURRENT
(AMPS)
ARC
VOLTAGE
(VOLTS)
WIRE FEED
SPEED
(m/min)
DEPOSITION
RATE (kg/hr)
0.8 30 17.0 2.4 0.6
0.8 60 19.0 5.8 1.4
0.8 90 21.0 9.2 22
0.8 120 230 12.6 3.0
0.8 150 25.0 16.0 3.9
0.9 35 17.0 2.5 0.8
0.9 75 20.0 5.6 1.7
0.9 120 235 9.1 2.7
0.9 165 26.5 12.5 3.8
0.9 210 30.0 16.0 4.8
1.0 35 16.0 1.5 0.6
1.0 80 18.0 4.2 1.6
1.0 130 21.0 7.1 2.6
1.0 180 24.0 10.1 3.7
1.0 225 26.0 12.7 4.7
1.2 50 17.0 1.5 0.8
1.2 100 19.5 2.8 1.5
1.2 150 22.0 4.1 2.2
1.2 200 24.5 5.3 2.8
1.2 250 27.0 6.6 3.5
1.2 300 295 7.9 4.2
1.2 350 32.0 9.1 4.8
Note: Deposition rate data obtained using:
A deposition effciency of 98% for pulsed arc transfer Ar + He + 1.5% CO
+ Short arc transfer conditions Note: Deposition rate data determined using:
DC+ (reverse polarity) with a conventional constant potential power source
Ar+ 1-2% O2 shielding gas An electrode stickout length of, 8-10mm for
short arc transfer conditions and 15mm for spray arc transfer conditions
A deposition effciency of 98% for both short arc transfer and spray arc
transfer conditions
163
CONTENTS
TABLES 3.5A TYPICAL DEPOSITION RATES USING GMAW
WITH AUSTMIG ALUMINIUM ALLOY WIRES (EG. AUSTMIG 5183)
TABLE 3.5B TYPICAL DEPOSITION RATES USING PULSED
ARC WELDING WITH AUSTMIG ALUMINIUM ALLOY WIRES
(EG. AUSTMIG 5183)
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SIZE
(mm)
WELDING
CURRENT
(AMPS)
ARC
VOLTAGE
(VOLTS)
WIRE FEED
SPEED
(m/min)
DEPOSITION
RATE (kg/hr)
0.9 100 17 9.2 0.9
0.9 125 18 10.9 1.1
0.9 175 21 15.0 1.5
0.9 200 22 18.0 1.7
1.2 150 22 7.8 1.4
1.2 175 23 9.0 1.6
1.2 225 05 13.8 2.4
1.2 250 25 13.8 2.4
WIRE
SIZE
(mm)
WELDING
CURRENT
(AMPS)
ARC
VOLTAGE
(VOLTS)
WIRE FEED
SPEED
(m/min)
DEPOSITION
RATE (kg/hr)
0.9 25 14.0 2.8 0.3
0.9 50 16.0 5.6 0.6
0.9 70 17.0 7.9 0.8
0.9 90 18.0 10.1 1.0
0.9 115 20.0 13.0 1.3
1.0 35 15.0 3.6 0.5
1.0 70 17.0 6.5 0.8
1.0 110 19.0 10.0 1.3
1.0 140 21.0 12.6 1.6
1.0 180 23.0 16.0 2.1
1.2 35 15.0 2.8 0.5
1.2 85 18.0 6.1 1.1
1.2 135 21.0 9.4 1.7
1.2 185 24.0 12.7 2.3
1.2 235 27.0 16.0 2.9
1.6 80 15.0 2.5 0.8
1.6 140 17.5 4.6 1.5
1.6 200 20.0 6.7 2.1
1.6 265 22.5 8.8 2.8
1.6 325 25.0 10.9 3.5
Note: Deposition rate data determined using:
Welding grade Ar shielding gas
A deposition effciency of 98% for pulsed arc transfer
Note: Deposition rate data determined using:
DC+ (reverse polarity) with a conventional constant potential power source.
Welding grade Ar shielding gas
An electrode stickout length of 20mm
A deposition effciency of 95%
164
CONTENTS
165
CONTENTS
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TABLES 3.6 MASS / LENGTH TABLES
PART A. LOW CARBON AND LOW ALLOY STEEL GMAW WIRES
PART B. FCAW WIRES
PART C. LOW CARBON AND LOW ALLOY STEEL SAW WIRES
PART D. STAINLESS STEEL WELDING WIRES
PART E. ALUMINIUM WELDING WIRES
DEPOSITION RATES
WIRE SIZE (mm) 0.6 0.8 0.9 1.0 1.2 1.6
GRAM OF WIRE PER
METRE
2.2 3.9 5.0 6.2 8.9 15.8
METRES OF WIRE
PER KG
450.5 253.7 200.4 161.3 112.7 63.4
WIRE SIZE (mm) 1.2 1.6 2.0 2.4 3.2
GRAM OF WIRE PER
METRE
7.6 13.0 20.0 28.0 50.1
METRES OF WIRE
PER KG
131.6 76.9 50.0 34.7 20.0
WIRE SIZE (mm) 2.0 2.4 3.2 4.0 4.8
GRAM OF WIRE PER
METRE
24.6 35.5 63.1 98.6 141.0
METRES OF WIRE
PER KG
40.6 28.2 15.9 10.1 7.0
WIRE SIZE (mm) 0.8 0.9 1.0 1.2 1.6
GRAM OF WIRE PER
METRE
4.1 5.1 6.3 9.0 16.0
METRES OF WIRE
PER KG
245 197.7 158 111.2 62.6
WIRE SIZE (mm) 0.8 0.9 1.0 1.2 1.6
GRAM OF WIRE PER
METRE
1.4 1.7 2.2 3.1 5.4
METRES OF WIRE
PER KG
712 528.2 455 327.5 184.2
166
CONTENTS
The deposition rates tabled in SECTION 3, are for a duty
cycle of 100% - that is continuous (uninterrupted) welding
of the consumable/arc process in question.
DUTY CYCLE IS, BY DEFINITION, A MEASURE OF THE ARC
ON TIME EXPRESSED AS A PERCENTAGE OF THE TOTAL
ELAPSED TIME, IE
DUTY CYCLES
Duty Cycle = (%)
arc time x 100
total elapsed time
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C
y
c
l
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%
100
80
60
40
20
0
Surfacing Operations
Automatic Welding
S
A
W
G
M
A
W

F
C
A
W
R
W
M
M
A
W
GW Manual Welding
Machine or
Mechanised Welding
Figure 4.0
This parameter indicates the proportion of the operating
time during which weld metal is actually being deposited. The
duty cycle can vary considerably according to a number
of factors including:
the welding process
the type of consumable
operating conditions
the application involved
the degree of mechanisation
general workshop effciency
a variety of human factors or personal allowances such
as putting gloves and helmet on, putting aside and
picking up electrode holder etc.
Figure 4.0 summarizes the potential range of duty cycles for
various arc welding processes and modes of operation.
167
CONTENTS
(a) Manual Metal-Arc Welding (MMAW)
The maximum obtainable duty cycle for MMAW is of the order of
65% but most applications will not permit a duty cycle greater than
50% to be achieved over a days production. The duty cycle for
MMAW operations varies widely with the type of application and
operating conditions. Electrode changes, slag removal, intermittent
welding and changing positions etc all play a part in reducing
the actual arc on time. With added delays, such as personal
allowances and materials handling, most welding workshops are
capable of maintaining duty cycles of 15-30%
(b) Gas Metal-Arc Welding (GMAW) and Flux Cored Arc
Welding (FCAW) Semi-automatic Arc Processes
For semi-automatic surfacing operations a duty cycle approaching
80% is possible. However, most GMAW and FCAW operates
between 30-60%; with mechanised semi-automatic welding yielding
duty cycles of 45-60% and conventional (or manual) semi-automatic
processes producing duty cycles of typically 30-40%.
(c) Submerged-Arc Welding (SAW)
For fully automatic hard surfacing operations, a 95% duty cycle
is possible with the submerged-arc process; however most
submerged-arc welding operates between 40-60% duty cycle due
to essential setting up, deslagging, loading / positioning and other
handling operations.
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CONTENTS
OPEN SQUARE GROOVE BUTT JOINT - WELDED BOTH SIDES
Reinforcement height, r = 2 mm.
JOINT DIMENSIONS
(MM)
Mass of steel weld
metal per metre.
(D) (kg/m)
Mass of MMAW**
electrodes required
per metre (M) (kg/m)
T R W
3 0 7 0.17 0.28
3 1 7 0.20 0.33
6 1.5 10 0.32 0.53
6 3 10 0.39 0.64
ELECTRODE CONSUMPTION
FOR TYPICAL BUTT JOINTS
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T
ELECTRODE CONSUMPTION FOR SOME COMMON BUTT
JOINTS
The following Tables provide useful data on the mass of weld
metal and MMAW electrodes required to complete some common
butt joints. Electrode consumption is calculated using the following
simple equation:
where M = Mass of electrodes required per metre of joint.
D = Mass of weld metal deposited per metre of joint.
P** = Proportion of electrode lost, due to spatter, slag
loss, stub end etc.
M =
D
1-P
169
CONTENTS
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JOINT
DIMENSIONS (MM)
Mass of steel weld
metal per metre.
(D) (kg/m)
Mass of MMAW**
electrodes required
T R L W
6 3.5 1.5 10.0 0.26 0.43
8 3.5 1.5 13.0 0.57 0.95
10 3.5 1.5 15.0 0.79 1.31
12 3.0 3.0 15.0 0.83 1.39
16 3.0 3.0 19.0 1.38 2.29
20 3.0 3.0 23.0 2.06 3.43
SINGLE V BUT JOINT
Reinforcement height, r = 2mm
W
60
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L
T
r
W
60
R
L T
r
JOINT
DIMENSIONS (MM)
Mass of steel weld
metal per metre.
(D) (kg/m)
Mass of MMAW**
electrodes required
T R L W
12 3.0 3.0 10.0 0.71 1.18
16 3.0 3.0 12.0 1.06 1.75
20 3.0 3.0 15.0 1.50 2.48
25 3.0 3.0 18.0 2.13 3.53
50 3.0 3.0 32.0 6.97 11.58
Single V But Joint
Reinforcement height, r = 2mm
For 380mm long EXX12, 13, 14, 16 & 18 type MMAW electrodes to AS/NZS
4855, P is typically 0.4. This fgure assumes a stub end length of 50mm.
(See table 2.0 for further details.)
170
CONTENTS
WELDABILITY GUIDE
FOR STEELS
The majority of steels in general use are considered Weldable
using most arc welding processes. The degree to which they are
rated as weldable is indicated by an imprecise term, Weldability
which is (as yet) not fully assessable by a laboratory test or series
of tests. We have included two different weldability guides to
assist you in determining preheat of materials. The frst guide is
the same as that used in Australian Standards and WTIA technical
notes the second guide is a method adopted by WIA and known
as the WIA Welability Guide
Furthermore, what is considered to be a satisfactory joint for one
set of service conditions, possibly, steel sections embedded in
concrete under static loading, may not be acceptable for another
set of service conditions, such as in the tension member of a
fexing structure or under corrosive conditions. For this reason,
no economically acceptable hard and fast rules can be
provided in a Guide such as this and the recommendations
should always be tempered in their translation into practice
with a knowledge of the intended application and other
factors relevant to the situation.
Arc welding is a process of intense localised heating and rapid
cooling, providing a sudden heating-quenching heat treatment
effect on both the weld metal and the adjacent parent metal
(HAZ). As a general rule the tendency of a steel to strengthen and
harden, following this heat treatment, increases as the carbon and
alloy content increases. Its composition is therefore an important
factor in assessing weldability.
CARBON EQUIVALENT
Carbon is the most effective of the commonly used alloying
elements in achieving increased strength and hardness (increased
hardenability) and is present in all steels. Over many years,
researchers have established numerous rating systems to
compare the hardening potential of other common elements such
as manganese and chromium against that of carbon. This has
led to the concept of calculating Carbon Equivalent (CE) from
the chemical composition of the steel as a means of assessing its
weldability. The following is the IIW formula used for determining
Carbon Equivalent from the percentage of elements present:
CE = C + + +
Mn Cr + Mo + V Ni + Cu
6 5 15
171
CONTENTS
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The Weldability Reference Numbers used in this guide, relate to
the following carbon equivalents:
NOTE: Reference numbers above 12 are not related to CE. In instances
where the ladle analysis is given for a steel, the maximum specifcation limits
have been used to calculate CE. For steels containing multiple alloy additions,
the use of maximum specifcation limits to calculate CE give conservative
results; because the possibility of all alloying elements simultaneously
achieving their maximum limit is remote. In these circumstances, it is
recommended that the CE be calculated using 80-85% of the ladle analysis
maximum specifcation limits.
OTHER FACTORS INFLUENCING WELDABILITY
Composition, although important, is not the only criterion used to assess the
weldability, of a given steel, in a given joint situation. Other infuences can
be broadly related either to their effect on the heat treatment or the stress
level of the joint.
CE
REFERENCE
NUMBER
CE
REFERENCE
NUMBER
below 0.30 1 0.55 to below 0.60 7
0.30 to below 0.35 2 0.60 to below 0.65 8
0.35 to below 0.40 3 0.65 to below 0.70 9
0.40 to below 0.45 4 0.70 to below 0.75 10
0.45 to below 0.50 5 0.75 to below 0.80 11
0.50 to below 0.55 6 0.80 and above 12
172
CONTENTS
WELDABILITY GUIDE
FOR STEELS
OTHER FACTORS INFLUENCING WELDABILITY
Factors which can have an effect on the heat treatment and
hence (with composition) the microstructure include; the mass
of the section, its initial temperature, the heat input per unit
length and the interpass temperature in multipass welds. Factors
which relate generally to the stress level include; the degree
of restraint imposed on the joint by its own mass and from
external sources, base metal strength (rigidity, hardness) and
geometry, uneven heating and cooling conditions and geometrical
considerations such as joint preparation and alignment, notches
due to weld contour, weld nugget shape and the presence of
non-metallic inclusions, etc. The tendency towards weld and
base metal cracking is further infuenced by the inherent
toughness and strength of the weld metal, the effect of base
metal dilution on these properties and the presence of hydroge
in the arc atmosphere.
NOTES ON USING THE GUIDE
The following pages list recommendations for welding some of
the more commonly available steels in Australia. Based primarily
on the steel composition, they assume moderate conditions of
restraint and joint complexity. Where low hydrogen or hydrogen
controlled conditions are nominated, electrodes should be dried
accordingly to meet the required level. For MMAW, the use of
4mm electrodes (minimum size) has been assumed, although the
user is expected to use the largest size practicable. The use of
higher and lower heat inputs by other electrode sizes or
processes can respectively lower and raise the recommended
preheat temperature.
Silicon levels are not listed for steels unless their content,
within a particular group, exceeds the normal maximum limit
of .35%, for other steels, typical Silicon fgures have been
quoted for interest sake. For further details regarding the
Sulphur, Phosphorus and Silicon levels in a particular steel,
refer to the manufacturers specifcation.
173
CONTENTS
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The term Combined Joint Thickness (CJT) is used in many
instances in conjunction with recommended preheat temperatures
as a measure of the quenching severity of the joint. For simple
butt and corner joints the CJT is the sum of each plate thickness,
whilst for more complex joints, such as T joints, the CJT can be
calculated as shown in fgure 11.
FIGURE 11 Combined Joint Thickness
(CJT) calculations for welds shown in black.
If t
is already welded
to

t

as shown

then:
CJT = t

+

t

+ t
CJT = t

+ 2t
If t
is already
welded to

t

then:
CJT = t

+

2t

+ t
t

= average
thickness
over 75mm
CJT = t

+ t
75mm
174
CONTENTS
WELDABILITY GUIDE
FOR STEELS
HYDROGEN CONTROL
The term low hydrogen or hydrogen controlled is not indicative
of no hydrogen, but of products and processes which have
controlled limits on moisture or hydrogen producing materials. The
fact that a product can meet the specifed requirements of a code
is not necessarily indicative of its ability to meet requirements in
more critical situations. Some codes have maximum permissible
moisture levels for lower strength electrodes and more stringent
requirements for higher strength. As a general rule, as the
retainability of the base material and weld metal increase, the
allowable maximum limit for hydrogen is reduced. This situation
is further complicated when restrictions are placed on preheat
temperature and heat input - which normally help to increase the
diffusion rate of hydrogen; such as for the welding of quenched
and tempered steels.
Flux coated hydrogen controlled electrodes when used in critical
applications should be thoroughly dry prior to use. If any doubt
exists, electrodes should be rebaked and used from a hot box.
WIA WELDABILITY REFERENCE NUMBERS AND
RECOMMENDATIONS
1&2 Readily weldable with any low carbon steel electrodes (for
example, Austarc 11, 12P, 13S, 24) or arc welding process
without special precautions.
1A Rimmed steels welded with the GTAW Process (TIG)
without added fller metal will give porous welds, due
to gas evolution, caused by resumption of the rimming
process. Use double deoxidised fller wire for sound joints.
2A The sulphur or lead content of these steels can lead to
hot shortness during welding and sulphur can also cause
porosity. Welding is therefore not generally recommended
except for non-critical applications. Basic coated,
MMAW electrodes such as Austarc 16TC, 18TC, 77
should be used or specially formulated electrodes for
welding sulphurised steels. The use of an intermediate
buffer pad is recommended in extreme cases and
through thickness joints are preferred to fllet welds.
No preheat required.
175
CONTENTS
3&4 Readily weldable with any low carbon steel electrode,
such as Austarc, 11, 12P, 13S, 24. For CJTs of 50mm or
greater a preheat temperature of 50-75C is recommended,
depending on the degree of restraint. Alternatively
hydrogen controlled electrode such as Austarc 16TC, 18TC
or 77 may be used with a preheat
temperature of only 25C.
3A As for 2A, but use 50C preheat on heavy sections.
3B Check if Shipping Society approval and specifc CVN
impact gradings are required for electrode,then as for 3
4B Check if Shipping Society approval and specifc CVN
gradings are required for electrode, then as for 4.
5 Conventional low carbon electrodes, such as Austarc
13S & 24 are still acceptable however,special notch
toughness requirements etc. may dictate a preference
for basic electrodes, particularly for butt welding
applications. The use of hydrogen controlled
basic electrodes, such as Austarc 16TC, 18TC & 77,
reduce the preheat temperature necessaryto prevent
HAZ weld metal cracking in highly restrained, heavy
sections. No preheat is generally required for CJTs up
to 40mm, welded with hydrogen controlled electrodes or
CJTs up to 30mm, welded with conventional low carbon
electrodes. When using conventional low carbon
electrodes, preheat joint to 50C for CJTs of 40mm,
and 125C for CJTs of 80mm. Using hydrogen controlled
electrodes, preheat joint to 50C for CJTs of 55mm and
100C for CJTs of 80mm and above. For welding with
semi automatic solid or fux cored wire like the Formula
XL-525, Austmig ES6 or Austmig 70C-6M etc. at a
heat input of 2.2kJ/mm, use a preheat temperature of
50C for CJTs of 80mm and above.
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176
CONTENTS
WELDABILITY GUIDE
FOR STEELS
WIA WELDABILITY REFERENCE NUMBERS
AND RECOMMENDATIONS
6A As for 5, except when matching colour and corrosion
resistance are required, an electrode
depositing a Ni-Cu weld metal is recommended.
6B Hydrogen controlled electrodes of matching weld metal
analysis and strength are normally recommended.
For minimum preheat temperatures, refer to 5.
6 Hydrogen controlled electrodes are generally considered
essential for the deposition of sound welds use a
preheat temperature of 70C for CJTs of 40mm. 100C
preheat for CJTs of 60mm and 150C preheat for CJTs
of 110 mm and above. When using semi automatic solid
or fux cored wire like the Formula XL-525, Austmig ES6
or Austmig 70C-6M etc., at approximately 2.2kJ/mm, a
preheat temperature of 50C is recommended for CJTs of
60mm and 125C for CJTs of 110mm and above.
7 Hydrogen controlled electrodes must be used with a
preheat temperature of 70C for CJTs of 28mm, 100C
for CJTs of 40mm and 170C for CJTs of 110mm and
above. For welding with appropriate solid or fux cored
wires, at approximately 2.2kJ/mm, a minimum preheat of
70C is required for CJTs of 45mm and 125C for CJTs
of 80mm. Slow cooling from interpass temperature is
required and critical weldments should be stress relieved.
7A Follow the general advice of 2A The welding of sulphur
bearing steels is not generally recommended, except for
non-critical applications. For general preheat requirements
refer to 7.
7B Hydrogen controlled electrodes of matching chemical
analysis and strength are recommended. The service
requirements of weldments employing this type of alloy
demand high integrity welding. A minimum preheat
temperature of 150C is generally recommended, for
CJTs of 30-60mm, followed by slow cooling. A stress
relieving heat treatment to 650C is common practice,
following welding.
177
CONTENTS
8 Use hydrogen controlled electrodes with a preheat
temperature of 75C for CJTs of 20mm. 120C for CJTs
of 40mm and 170C for CJTs of 80mm. For semi-
automatic welding with appropriate solid or fux cored
wires, at approximately 2.2kJ/mm, use a preheat of
100C for CJTs of 40mm, and 200C for CJTs of 100mm.
Slow cooling is essential, followed by a stress relieving
heat treatment for critical joints.
9 Use hydrogen controlled electrodes such as Austarc
16TC, 18TC or 77 with a minimum preheat of 90C for
CJTs of 20mm, 150C for CJTs of 40mm and 200C for
CJTs of 80mm. For semi-automatic welding with
appropriate solid or fux cored wires, at approximately
2.2kJ/mm, a minimum preheat of 50C is recommended
or CJTs of 20mm, 120C for CJTs of 40mm and 180C for
CJTs of 80mm.
9A Follow the general advice of 2A. The welding of sulphur
bearing steels is not generally recommended, except for
non-critical applications. For general preheat
requirements, refer to 9.
10&11 Use hydrogen controlled electrodes such as Austarc
16TC, 18TC or 77 which have been thoroughly dried,
with the following minimum preheat temperatures.
Alternatively use austenitic, stainless steel electrodes such as
Unicord 312 with preheat temperatures approximately 50C
less than those recommended above for hydrogen controlled
electrodes. The use of dry electrodes is essential, as is slow
cooling after welding. A post weld heat treatment is considered
good welding practice.
CJT WIA WELDABILITY
20 mm 40 mm 80mm REF: NUMBER
120C 170C 220C 10
140C 190C 230C 11
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178
CONTENTS
WELDABILITY GUIDE
FOR STEELS
RECOMMENDATIONS
11A Following the general advice of 2A. The welding of
higher carbon, sulphur bearing steels is not generally
recommended, except for non-critical applications For
general preheating requirements, refer to 11.
9C, 11C For high strength butt and flet welding of these steels,
use Hydrogen controlled electrode & 12C
of matching chemical analysis or strength. Refer to the
minimum preheat temperatures and welding details
described in 9,11 and 12 respectively. When welding
these steels in the heat treated (hardened and
tempered) condition check that the post weld heat
treatment temperature chosen does not exceed the
tempering temperature of the base material.
10B, 11B The welding of alloy spring steels in the heat treated
(hardened and tempered) condition
& 12B can be carried out using preheat and interpass
temperatures of 200-300C, with extra slow cooling in
insulating powder, a lime bath or a thermal blanket
etc. Austarc 16TC, 18TC and 77 is recommended for
root pass welding whilst subsequent higher strength
passes may be made with high strength electrode eg.
AWS A5.5: E110XX. Thoroughly dried electrodes
are essential and post weld heat treatment is generally
not recommended.
12 Use hydrogen controlled electrodes-in thoroughly dry
condition, with the following minimum preheat temperatures:
CJT WIA WELDABILITY
20 mm 40 mm 80mm REF: NUMBER
170C 220C 260C 12
179
CONTENTS
Welding on these steels is preferred in the annealed condition
and low dilution techniques should be employed. Under higher
degrees of restraint a further 50C of preheat is recommended to
avoid cracking. In some applications, the use of Unicord 312 is
acceptable, especially where high preheats are diffcult to achieve.
Dry electrodes and clean joints are essential. Slow cooling followed
by a PWHT immediately after welding is a compulsory practice.
13 Arc welding of these steels should be avoided if
possible. Welding is best carried out on tool steels in
the annealed condition, however, repair work on heat
treated (hardened and tempered) material or minor
attachments can be welded with Unicord 312. A preheat
temperature of 150-500C is required as is a Post Weld
Heat Treatment (PWHT) of 150-650C for exact heat
treatment details refer to manufacturers data on the tool
steel being welded. It is important that the PWHT
temperature chosen does not exceed the tempering
temperature of the tool or mould steel being welded.
Hydrogen controlled ferritic electrodes, such as Austarc
16TC, 18TC and 77, should only be used on annealed
tool steels, with accordingly higher preheat temperatures.
14 Should be welded with hydrogen controlled electrodes
or wires of matching chemical analysis and strength.
Low hydrogen conditions are essential. Preheat
and interpass temperatures of the order of 250C-300C
are recommended followed by retarded cooling and a
stress relieving heat treatment of 650-700C.
14A As for 14, except that a matching 5% Cr - 1/2 Mo
hydrogen controlled electrode is essential for matching
strength and corrosion. An alternative approach of using
Unicord 312 is acceptable for joints not subject to
thermal fatigue conditions and allows the use of lower
preheat temperatures and higher interpass temperatures.
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180
CONTENTS
WELDABILITY GUIDE
FOR STEELS
RECOMMENDATIONS
15 Should be welded with a type 420 fller metal for
matching chemical analysis and mechanical properties.
However, Staincord 309Mo-16, Unicord 312 are suitable
austenitic, stainless steel electrodes for repair welds.
A preheat and interpass temperature of 200C is
recommended, immediately followed by a post weld
heat treatment of 370C. Allow component to cool to
40C and post heat a second time, to ensure
optimum properties.
16 This class of alloy is best treated by water quenching
during welding and remains a tough austenitic structure,
unless reheated above 400C. Use 1220-A4 type electrode,
for build-up or reclamation and Unicord 312 for butt and
fllet welds. The base metal should be kept cool during
welding by intermittent quenching, skip welding etc.
17 The use of hydrogen controlled consumables is compulsory
for welding Quenched and Tempered (Q & T) steels.
Electrodes and wires providing matching strength to
the structural grades are recommended for butt welding,
however, consumables of under-matching strength such as
Austarc 18TC, 77 may be suitable for fllet welding
applications on both structural and abrasion resistant grades.
Because of the risk of stress relief cracking, post weld heat
treatment of Q & T steels should not be undertaken, unless
absolutely necessary. If so stress relieving temperatures should
not exceed the tempering temperature of the Q & T steel being
welded. Refer to WTIA Technical Note 15 for complete details
on the welding of Q & T steels. The following minimum pre-heat
temperatures, maximum interpass temperatures and maximum
arc heat input energies should be used as a guide for welding
both structural and abrasion resistant grades of Q & T steels.
181
CONTENTS
GRADE OF Q & T STEEL <13 13 ~15 25 ~50 <50
MINIMUM PREHEAT TEMPERATURES
(C) (HIGH RESISTANT)
HIGH STRENGTH GRADES
450 MPa min. Yield Stress 10 25 75 10
ABRASION RESISTANT GRADES
320 HB (3000/10) 50 100 125 150
360 HB (3000/10) 50 100 125 15
500 HB (3000/10) 100 100 150 -
ALL GRADES
MAXIMUM INTERPASS
TEMPERATURES (C)
150 175 200 220
ALL GRADES
MAXIMUN ARC HEAT INPUT (kj/mm)
2.5 3.5 4.5 5.0
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182
CONTENTS
WELDABILITY GUIDE
FOR STEELS
STEEL TYPES
FREE MACHINING STEELS
STEEL
DESIGNATION
CHEMICAL ANALYSIS (%)
WIA
WELDABILITY
REF: NUMBER
C Mn
LOW CARBON AND MILD STEELS
1008 .10 max .20-.50 1,1A
1020 .18-23 .30.60 3
1022 .18-23 .70-1.00 4
1025 .22-28 .30-60 4
MEDIUM CARBON STEELS
1030 .28-.34 .60-.90 5
1035 .32-.38 .60-.90 6
X 1038 .35-.42 .70-1.00 8
1040 .37-.44 .60-.90 7
1045 .43-.50 .60-.90 7
HIGH CARBON STEELS
1050 .48-55 .60-.90 10
1055 .50-.60 .60-.90 11
1060 .55-.60 .60-.90 11
1070 .65-.75 .60-.90 12
STEEL
DESIGNATION
WIA
WELDABILITY
REF:
NUMBER
C Mn S Pd
RESULPHURISED AND RESULPHERISED-REPHOSPHORISED GRADES
1110 .06-.11 .30-.60 .05-1.0 - 2A
X1112 .08-.15 1.10-1.40 .20-.30 - 3A
1214 .15 max .80-1.20 .25-.35 - 3A
1137 .32-.39 1.35-1.65 .08-.13 - 9A
1144 .40-.48 1.35-1.65 .08-.13 - 11A
1146 .42-.49 .701-.00 0.089-.13 - 9A
X1147 .40-.47 1.60-1.90 .10-.35 - 11A
RESULPHURISED AND RESULPHERISED-REPHOSPHORISED GRADES
12L14 .15 max .80-1.20 .25-.35
.15
-.35
2A
183
CONTENTS
STEEL TYPES
STEEL
DESIGNATION
WIA
WELDABILITY
REF: NUMBER
C Mn
CARBON-MANGANESE STEELS
X1320 .18-.23 1.40-1.70 5
X1325 .23-.28 1.40-1.70 6
X1330 .28-.33 1.40-1.70 8
X1340 .38-.43 1.40-1.70 10
STEEL
DESIGNATION
WIA
WELDABILITY
REF:
NUMBER
C Mn Si Cr
SPRING STEELS
XK 55S .50-.60 .70-1.00 .10-.35 .70-.90 11B
XK 5160S .50-.65 .70-1.00 .10-.35 .70-.90 12B
XK 9258S .50-.65 .70-1.05 1.60-2.20 - 12B
XK 9261S .50-.65 .70-1.00 1.80-2.20 1 12B
ALLOY STEELS (FOR OTHER THAN SPRING APPLICATIONS)
5155 .50-.60 .70-1.00 .10-.35 .70-.90 11
5160 .55-.65 .70-1.00 .10-.35 .70-.90 12
9255 .50-.60 .70-1.05 1.60-2.20 - 12
9261 .50-.65 .70-1.00 1.80-2.20 .10-.25 12
STEEL
DESIGNATION
WIA
WELDABILITY
REF:
NUMBER
C Mn Si Ni Cr Mo Other
ALLOY CONSTRUCTION STEELS
4140 .40 .60 .25 - .90 .20 - 12C
XK 4150 .50 1.30 .25 - .65 .18 5.08 12C
4340 .40 .60 .25 1.50 1.0 .25 - 12C
XX9931(en 26) .30 .60 .25 2.50 .50 .20 - 11C
XX9940 (en 26) .40 .60 .25 2.50 .50 .20 - 12C
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184
CONTENTS
WELDABILITY GUIDE
FOR STEELS
STEEL TYPES
STEEL
DESIGNATION
WIA WELD-
ABILITY
REF:
NUMBER
C Mn Si Ni Cr Mo Other
CASE HARDENING STEELS
4620 .20 .50 .25 1.75 - .25 - 6
8620 .20 .80 .25 .50 .50 .20 - 5
En 36A .12 .50 .25 3.20 .90 - - 9C
XK9315 (en 398) .15 .50 .25 4.20 1.20 .20 - 12
STEEL
DESIGNATION
WIA
WELDABILITY
REF: NUMBER
C Mn SI Cr
FERRITIC CREEP RESISTANT STEELS
Mn-Mo .20 1.40 - .45 7B
1/2Cr - 1/2Mo .15 .50 .50 .50 7B
1Cr - 1/2Mo .12 .50 1.10 .50 7B
2 1/4Cr - 1Mo .12 .50 2.30 1.0 14
5Cr - 1/2Mo .12 .50 5.00 .60 14A
185
CONTENTS
STEEL TYPES
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186
CONTENTS
WELDABILITY GUIDE
FOR STEELS
STEEL TYPES
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187
CONTENTS
STEEL TYPES
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L

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T
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G
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D
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F
O
R

S
T
E
E
L
S
188
CONTENTS
WELDABILITY GUIDE
FOR STEELS
STEEL TYPES
S
T
E
E
L

D
E
S
I
G
N
A
T
I
O
N
C
H
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A
N
A
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Y
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I
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(
%
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A

W
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F
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M
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2
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3
189
CONTENTS
STEEL TYPES
S
T
E
E
L

D
E
S
I
G
N
A
T
I
O
N
C
H
E
M
I
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A
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(
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S
T
E
E
L
S
190
CONTENTS
WELDABILITY GUIDE
FOR STEELS
STEELS TO SHIPPING CLASSIFICATION SOCIETY RULES
Single values unless otherwise stated are maxima.
STEEL
DESIGNATION
CHEMICAL ANALYSIS (5)
WIA
WELDABILITY
REF: NUMBER
C Mn
LLOYDS REGISTER OF SHIPPING
GRADE A .23 - 3B
GRADE B .21 .80 min 3B
GRADE D .21 .60 min 4B
GRADE E .18 .70 min 4B
AMERICAN BUREAU OF SHIPPING
CLASS A .23 - 3B
CLASS B .21 .80-1.10 4B
CLASS CS .16 1.00-1.35 3B
CLASS DS .16 1.00-1.35 3B
CLASS D .21 .70-1.35 4B
CLASS E .18 .70-1.35 4B
DET NORSKE VERITAS
GRADE NVA .23 - 3B
GRADE NVD .21 .60 min 4B
GRADE NVE .18 .70 min 4B
BUREAU VERTITAS
GRADE A - - 3B
GRADE B .21 .80-1.40 3B
GRADE D .21 .60-1.40 4B
GRADE E .18 .70-1.50 4B
191
CONTENTS
STEEL TYPES - QUENCHED AND TEMPERED STEELS
(A) (A) HIGH STRENGTH STRUCTURAL STEELS
S
T
E
E
L

D
E
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S
T
E
E
L
S
192
CONTENTS
193
CONTENTS
WELDABILITY GUIDE
FOR STEELS
STEEL TYPES - QUENCHED AND TEMPERED STEELS
(B) ABRASION RESISTANT GRADES
S
T
E
E
L

D
E
S
I
G
N
A
T
I
O
N
B
R
I
N
D
A
L

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A
R
D
-

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S
S

(
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B
)
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A
L

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C
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L

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A
L
Y
S
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A
N
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(
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)
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D
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L
A
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T
H
I
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K
N
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S
S
)
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I
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W
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L
D
A
B
I
L
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Y

R
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F
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C
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S
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7
W
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N

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m
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n
.
1
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2
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4
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0
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W
E
L
D
A
B
I
L
I
T
Y

G
U
I
D
E

F
O
R

S
T
E
E
L
S
194
CONTENTS
COMMON WELDING
TROUBLES
CRACKED
WELDS
2
POROUS
WELDS
3
POOR
PENETRATION
4
UNDERCUTTING
1
195
CONTENTS
LACK OF
FUSION
5
INCLUSIONS
6
OVERLAPPING
7
SPATTER
8
C
O
M
M
O
N

W
E
L
D
I
N
G

T
R
O
U
B
L
E
S
196
CONTENTS
WHY
1. Faulty electrode
manipulation
2. Welding current too high
3. Too long an arc length
4. Too fast travel speed
5. Arc blow
WHAT TO DO
1. Pause at each side of the
weld bead when using a
weaving technique
2. Use proper electrode angles
3. Use proper welding current
for electrode size and
welding position
4. Reduce arc length
5. Reduce travel speed
6. Reduce effects of arc blow
UNDERCUTTING
1
CRACKED WELDS
2
WHY
1. Insuffcient weld size
2. Excessive joint restraint
3. Poor joint design
and/or preparation
4. Filler metal does not
match base metal
5. Rapid cooling rate
6. Base metal surface covered
with oil, grease, moisture,
rust, dirt or mill scale
WHAT TO DO
1. Adjust weld size to
part thickness
2. Reduce joint restraint
through proper design
3. Select the proper
joint design
4. Use more ductile fller
5. Reduce cooling rate
through preheat
6. Properly clean base
metal prior to welding
COMMON WELDING
TROUBLES
197
CONTENTS
C
O
M
M
O
N

W
E
L
D
I
N
G

T
R
O
U
B
L
E
S
POROUS WELDS
3
POOR PENETRATION
4
WHY
1. Excessively long or
short arc length
3. Insuffcient or damp
shielding gas
4. Too fast travel speed
5. Base metal surface
covered with oil, grease,
moisture, rust, mill
scale, etc
WHAT TO DO
1. Maintain proper arc length
2. Use proper welding current
3. Increase gas fowrate and
check gas purity
5. Properly clean base metal
prior to welding
6. Properly maintain and
store electrode
WHY
1. Travel speed too fast
2. Welding current too low
3. Poor joint design
and/or preparation
4. Electrode diameter too large
5. Wrong type of electrode
6. Excessively long arc length
WHAT TO DO
1. Decrease travel speed
2. Increase welding current
3. Increase root opening or
decrease root face
4. Use smaller electrode
5. Use electrode with deeper
penetration characteristics
198
CONTENTS
LACK OF FUSION
5
INCLUSIONS
6
WHY
1. Incomplete slag removal
between passes
2. Erratic travel speed
3. Too wide a weaving motion
4. Too large an electrode
5. Letting slag run ahead
of arc
6. Tungsten spitting or sticking

WHAT TO DO
1. Completely remove slag
between passes
2. Use a uniform travel speed
3. Reduce width of weaving
technique
4. Use a smaller electrode size
for better access to joint
5. Increase travel speed or
change electrode angle or
reduce arc length
6. Properly prepare tungsten
and use proper current
WHY
1. Improper travel speed
2. Welding current too low
3. Faulty joint preparation
diameter
5. Magnetic arc blow
6. Wrong electrode angle
WHAT TO DO
2. Increase welding current
3. Weld design should allow
electrode accessibility to all
surfaces within the joint
4. Reduce electrode diameter
5. Reduce effects of magnetic
arc blow
6. Use proper electrode angles
COMMON WELDING
TROUBLES
199
CONTENTS
C
O
M
M
O
N

W
E
L
D
I
N
G

T
R
O
U
B
L
E
S
OVERLAPPING
7
SPATTER
8
WHY
1. Too slow travel speed
2. Incorrect electrode angle
WHAT TO DO
1. Increase travel speed
2. Use proper electrode
angles
3. Use a smaller electrode
size
WHY
1. Arc blow
3. Too long an arch length
4. Wet, unclean or damaged
electrode
WHAT TO DO
1. Attempt to reduce the
effect of arc blow
2. Reduce welding current
4. Properly maintain and
store electrodes
200
CONTENTS
SI UNITS AND
CONVERSION DATA
AUSTRALIAN INDUSTRY IS NOW FULLY CONVERTED TO
THE S.I. (SYSTEME INTERNATIONAL) SYSTEM OF UNITS.
In the S.I. system there are seven base units, from which other
units are derived:
QUANTITY NAME SYMBOL
length metre m
mass kilogram kg
time second s
electric current ampere A
Thermodynamic temperature kelvin K
luminous intensity candela cd
amount of substance mole mol
In the S.I. system the use of factor notations, such as 10 or 10
,
are avoided by the use of S.I. prefxes to indicate submultiples and
multiples. The prefxes used to denote these, together with their
appropriate symbols are shown as follows:
Therefore, for example, one millionth of a metre of .000001 m is
expressed as one micrometre or 1 um. Some countries employ
different unit systems, such as the U.S.A. which uses the imperial
system. The following data is provided to assist the user in
converting to locally accepted units.
LENGTH: 1mm = .03937 in = 39 thousandths of an inch
1 m = 39.3701 in 1 in = 25.4mm
1 m = 3.2808 ft 1 ft = 0.3048m
1 m = 1.0936 yd 1 yd = 0.9144 m
1 km = 49.7097 chain 1 chain = 20.1168 m
1 km = 0.6214 mile 1 mile = 1.6093 km
PREFIX X SYMBOL PREFIX X SYMBOL
deca 10 da deci 10
d
hecto 10
h cent 10
c
kilo 10
k milli 10
m
mega 10 M micra 10
u
giga 10
G nano 10
n
201
CONTENTS
AREA: 1 mm
=. 00155 in
1 in
= 645.16 mm

1 m

= 1,550 in

1 m
= 10.7639 ft
1 ft
= .0929 m

1 m
= 1.19599 yd
1 yd
= .8361 m

1 ha = 2.4710 acre 1 acre = .4047 ha
1 km
= .3861 sq mile 1 sq mile = 2.5899 km
VOLUME: 1 cm
= .06102 in
1 in
= 16.3871 cm

1 m
= 35.3147 ft
1 ft
= .0282 m

1 m
= 1.3080 yd
1 yd
= .7646 m

1 dm
= 1 litre = 61.0237 in
1000 litres = 1m

1 dm
= .2200 gal 1 gal = 4.5461 dm

1 dm
= 0.8799 qt 1 qt = 1.1365 dm

1 dm
= 1.7598 pt 1 pt = 0.5683 dm

1 dm
= 0.2642 US gal 1 US gal = 3.7854 dm
MASS: 1 kg = 35.2740 oz 1 oz = 28.3495 g

1 kg = 2.2046 lb 1 lb = 0.4536 kg
1 kg = 0.1575 stone 1 stone = 6.3503 kg
1,000 kg = 1t = 19.6841 cwt 1 cwt = 50.8023 kg
1t = 0.9842 ton 1 ton = 1.01605 t
1t = 2204.6 lb 1 ton = 22040 lb
SPEED: 1 in/min = 25.4 mm/min
1 rn/hr = 16.7 mm/min
1 mm/min = 0.20 ft/hr
1 in/min = 5.0 ft/hr
see table 2 tor Travel and Wire Speed Conversion Tables
FLOW 1 L/min = 2.119 ft
/hr 1 ft
/hr = 0.472 L/min

RATE: 1 L/min = 0.264 gal/min 1 US gal/min = 3.785 L/min
1 ft
/hr = 0.125 US gal/min 1 US gal/min = 8.021 ft
/hr
S
I

U
N
I
T
S

A
N
D

C
O
N
V
E
R
S
I
O
N

D
A
T
A
LENGTH: 1mm = .03937 in = 39 thousandths of an inch
1 m = 39.3701 in 1 in = 25.4mm
1 m = 3.2808 ft 1 ft = 0.3048m
1 m = 1.0936 yd 1 yd = 0.9144 m
1 km = 49.7097 chain 1 chain = 20.1168 m
1 km = 0.6214 mile 1 mile = 1.6093 km
202
CONTENTS
SI UNITS AND
CONVERSION DATA
TEMPERATURE
The S.I. units of temperature is strictly speaking the Kelvin, K. The
temperature unit used widely in Australia and recognised for use
in the S.I. system, is however, the degree Celsius - C. Degree
Celsius (C) is related to Kelvin (K) by the following formula:
Temperature in Kelvin (K) = Temperature in degrees Celsius (C)
+ 273.15. Therefore, the zero point for Celsius temperature, 0C,
is exactly equal to 273.15K. Another temperature unit still used in
some countries is the degree Fahrenheit. F - refer to table 3 for
0C F Temperature Conversions.
HARDNESS
Refer to table 4 for a comparison of Hardness Scales
STRESS
In the S.I. system, the unit of stress is the newton per square metre,
N/m
, more popularly known as the pascal (symbol Pa). One

pascal represents only a very small unit of stress, so the multiples,
kN/m2 or kPa and MN/m
or MPa, are frequently used. In the metric

system the unit of stress is the kgf/mm
whilst the imperial system

uses both ton f/in
(TSI) and lbf/in
(psi) to defne stress.

NB. 1 MPa = 1 MN/m
= 1 N/mm
-1,000 kPa
1 MPa = 0.0647 ton f/in
(TSI) 1TSI = 15.456 MPa

1 MPa = 145.038 lb f/in
(psi) 1 psi = .0069 MPa

N.B. (70 MPa equivalent
to 10,000 psi)
1 MPa = 0.1020 kgf/ mm
1 kgf/ mm
= 9.804 MPa
Refer to table 5 for conversion to various Stress units.
203
CONTENTS
S
I

U
N
I
T
S

A
N
D

C
O
N
V
E
R
S
I
O
N

D
A
T
A
PRESSURE
The units of Stress and Pressure are, of course, interchangeable
however some of the more popular units used for defning gas and
atmospheric pressure are:
1 lbft/in
(psi) = 6,895 Pa
N.B. (14.5 psi equivalent to 100 kPa) 1 ksi = 1000 psi
1 kPa = 10-2 b (bar) lb = 105 Pa
1 kPa = 9.869 x 10-3atm 1 atm = 1.013 x l05 Pa
1 kPa = 7.501 mmHg 1 mm Hg - 133.3 Pa
IMPACT ENERGY
In the S.I. system the unit of energy is the joule, J. In the widely
employed Charpy-Vee Notch Impact Test the joule is the unit
used. One joule, J, is equivalent to 1 newton (force) x 1 metre
(distance) in the S.I. system.In metric countries the energy fgure
commonly quoted is the kilogram metre, kgfm, whilst the imperial
system commonly uses the foot pound, ft lbf.
1 J = 0.7376 ft lbf 1 ft lbf = 1.3558J
1 J = 0.1020 kgfm 1 kgfm = 9.8066
Refer to the Impact Energy Conversion table 5
DENSITY
The S.I. unit of density is the kilogram per cubic metre, kg/in
.
In the metric system the unit of density is the gram per cubic
centimetre, g/cm
. The pound per cubic inch, lb/in
, and the pound

per cubic foot, lb/ft
are units frequently used in the imperial system.

1 kg/m
= 10-3 g/cm
1 g/cm
= 1,000 kg/m

1 kg/m
= 36.1273 x 10-6 lb/in
1 lb/in
= 27,679.9 kg/m

1 kg/m
= .0624 lb/ft
1 lb/ft
= 16.0185 kg/m
Some weld metal densities worth noting are:

Mild Steel 7.85 x 10
kg/m

Stainless Steel 7.95 x 10
kg/m

Aluminium 2.7 x lO
kg/m

Tin Bronze 8.9 x 10
kg/m
204
CONTENTS
CONVERSION FROM
INCHES TO MM
I
N
C
H

(
F
r
a
c
t
i
o
n
)
I
N
C
H

(
D
e
c
i
m
a
l
)
M
M
I
N
C
H

(
F
r
a
c
t
i
o
n
)
I
N
C
H

(
D
e
c
i
m
a
l
)
M
M
I
N
C
H

(
F
r
a
c
t
i
o
n
)
I
N
C
H

(
D
e
c
i
m
a
l
)
M
M
1
/
6
4
0
.
0
1
5
8
0
.
3
9
6
9
1
1
/
3
2
0
.
3
4
3
7
8
.
7
3
1
2
4
3
/
6
4
0
.
6
7
1
9
1
7
.
0
6
5
6
1
/
3
2
0
.
0
3
1
2
0
.
7
9
3
7
2
3
/
6
4
0
.
3
5
9
4
9
.
1
2
8
1
1
1
/
1
6
0
.
6
8
7
5
1
7
.
4
6
2
5
3
/
6
4
0
.
0
4
6
9
1
.
1
9
0
6
3
/
8
0
.
3
7
5
9
.
5
2
5
4
5
/
6
4
0
.
7
0
3
1
1
7
.
8
5
9
4
1
/
1
6
0
.
0
6
2
5
1
.
5
8
7
5
2
5
/
6
4
0
.
3
9
0
6
9
.
9
2
1
9
2
3
/
3
2
0
.
7
1
8
7
1
8
.
2
5
6
2
5
/
6
4
0
.
0
7
8
1
1
.
9
8
4
4
1
3
/
3
2
0
.
4
0
6
2
1
0
.
3
1
8
7
4
7
/
6
4
0
.
7
3
4
4
1
8
.
6
5
3
2
3
/
3
2
0
.
0
9
3
7
2
.
3
8
1
2
2
7
/
6
4
0
.
4
2
1
9
1
0
.
7
1
5
6
3
/
4
0
.
7
5
0
1
9
.
0
5
0
7
/
6
4
0
.
1
0
9
4
2
.
7
7
8
1
7
/
1
6
0
.
4
3
7
5
1
1
.
1
1
2
5
4
9
/
6
4
0
.
7
6
5
6
1
9
.
4
4
6
9
1
/
8
0
.
1
2
5
3
.
1
7
5
2
9
/
6
4
0
.
4
5
3
1
1
1
.
5
0
9
4
2
5
/
3
2
0
.
7
8
1
2
1
9
.
8
4
3
3
9
/
6
4
0
.
1
4
0
6
3
.
5
7
1
9
1
5
/
3
2
0
.
4
6
8
7
1
1
.
9
0
6
2
5
1
/
6
4
0
.
7
9
6
9
2
0
.
2
4
0
2
5
/
3
2
0
.
1
5
6
2
3
.
9
6
8
7
3
1
/
6
2
0
.
4
8
4
4
1
2
.
3
3
1
1
3
/
1
6
0
.
8
1
2
5
2
0
.
6
3
7
5
1
1
/
6
4
0
.
1
7
1
9
4
.
3
6
5
6
1
/
2
0
.
5
0
0
1
2
.
7
0
0
5
3
/
6
4
0
.
8
2
8
1
2
1
.
0
3
4
4
3
/
1
6
0
.
1
8
7
5
4
.
7
6
2
5
3
3
/
6
4
0
.
5
1
5
6
1
3
.
0
9
6
8
2
7
/
3
2
0
.
8
4
3
7
2
1
.
4
3
1
2
1
3
/
6
4
0
.
2
0
3
1
5
.
1
5
9
4
1
7
/
3
2
0
.
5
3
1
2
1
3
.
4
9
3
7
5
5
/
6
4
0
.
8
5
9
4
2
1
.
8
2
8
1
7
/
3
2
0
.
2
1
8
7
5
.
5
5
6
2
3
5
/
6
4
0
.
5
4
6
9
1
3
.
8
9
0
6
7
/
8
0
.
8
7
5
2
2
.
2
2
5
0
1
5
/
6
4
0
.
2
3
4
4
5
.
9
5
3
1
9
/
1
6
0
.
5
6
2
5
1
4
.
2
8
7
5
5
7
/
6
4
0
.
8
9
0
6
2
2
.
6
2
1
9
1
/
4
0
.
2
5
6
.
3
5
3
7
/
6
4
0
.
5
7
8
1
1
4
.
6
8
4
4
2
9
/
3
2
0
.
9
0
6
2
2
3
.
0
1
8
7
1
7
/
6
4
0
.
2
6
5
6
6
.
7
4
6
9
1
9
/
3
2
0
.
5
9
3
7
1
5
.
0
8
1
2
5
9
/
6
4
0
.
9
2
1
9
2
3
.
4
1
5
6
9
/
3
2
0
.
2
8
1
2
7
.
1
4
3
7
3
9
/
6
4
0
.
6
0
9
4
1
5
.
4
7
8
1
1
5
/
1
6
0
.
9
3
7
5
2
3
.
8
1
2
5
1
9
/
6
4
0
.
2
9
6
9
7
.
5
4
0
6
5
/
8
0
.
6
2
5
1
5
.
8
7
5
6
1
/
6
4
0
.
9
5
3
1
2
4
.
2
0
9
4
5
/
1
6
0
.
3
1
2
5
7
.
9
3
7
5
4
1
/
6
4
0
.
6
4
0
6
1
6
.
2
7
1
9
3
1
/
3
2
0
.
9
6
8
7
2
4
.
6
0
6
2
2
1
/
6
4
0
.
3
2
8
1
8
.
3
3
4
4
2
1
/
3
2
0
.
6
5
6
2
1
6
.
6
6
8
7
6
3
/
6
4
0
.
9
8
4
4
2
5
.
0
0
3
1
205
CONTENTS
S
I

U
N
I
T
S

A
N
D

C
O
N
V
E
R
S
I
O
N

D
A
T
A

TRAVEL AND WIRE
FEED SPEEDS
INCHES
PER MIN
FEET
PER HR
MM
PER MIN
CM
PER MIN
M
PER MIN
M
PER HR
3 15 76 7.6 .08 4.6
4 20 102 10.2 .10 6.1
5 25 127 12.7 .13 7.6
6 30 152 15.2 .15 9.1
8 40 203 20.3 .20 12.2
10 50 254 25.4 .25 15.2
12 60 305 30.5 .30 18.3
14 70 356 35.6 .36 21.3
16 80 406 40.6 .41 24.4
18 90 457 45.7 .46 27.4
20 100 508 50.8 0.51 30.5
22 110 559 55.9 .56 33.5
24 120 610 61.0 .61 36.6
26 130 660 66.0 .66 39.6
28 140 711 71.1 .71 42.7
30 150 762 76.2 .76 45.7
32 160 813 81.3 .81 48.8
34 170 864 86.4 .86 51.8
36 180 914 91.4 .91 54.9
38 190 965 96.5 .97 57.9
40 200 1016 101.6 1.02 61.0
45 225 1143 114.3 1.14 68.6
50 250 1270 127.0 1.27 76.2
55 275 1397 139.7 1.40 83.8
60 300 1524 152.4 1.52 91.4
65 325 1651 165.1 1.65 99.1
70 350 1778 177.8 1.78 106.7
75 375 1905 190.5 1.91 114.3
80 400 2032 203.2 2.03 121.9
85 425 2159 215.9 2.16 129.5
90 450 2286 228.6 2.29 137.2
95 475 2413 241.3 2.41 144.8
100 500 2540 254.0 2.54 152.4
INCHES/
MIN
M/MIN
INCHES/
MIN
M/MIN
INCHES/
MIN
M/MIN
110 2.79 200 5.08 425 10.80
120 3.05 225 5.72 450 11.43
130 3.30 250 6.35 475 12.07
140 3.56 275 6.99 500 12.70
150 3.81 300 7.62 525 13.34
160 4.06 325 8.26 550 13.97
170 4.32 350 8.89 575 14.61
180 4.57 375 9.53 600 15.24
190 4.83 400 10.16 625 15.88
206
CONTENTS
C F C F
C F C F
-101 -150 -238 5.00 41 105.8
-95.6 -140 -220 5.56 42 107.6
-90.0 -130 -202 6.11 43 109.4
-84.4 -120 -184 6.67 44 111.2
-78.9 -110 -166 7.22 45 113.0
-73.3 -100 -148 7.78 46 114.8
-67.8 -90 -130 8.33 47 116.6
-62.2 -80 -112 8.89 48 118.4
-56.7 .70 -94 9.44 49 120.2
-51.1 -60 -76 10.0 50 122.0
-45.6 -50 -58 10.6 51 123.8
-40.0 -40 -40 11.1 52 125.6
-34.4 -30 -22 11.7 53 127.4
-28.9 -20 -4 12.2 54 129.2
-23.3 -10 14 12.8 55 131.0
-17.8 0 32 13.3 56 132.8
-17.2 1 33.8 13.9 57 134.6
-16.7 2 35.6 14.4 58 136.4
-16.1 3 37.4 15.0 59 138.2
-15.6 4 39.2 15.6 60 140.0
-15.0 5 41.0 16.1 61 141.8
-14.4 6 42.8 16.7 62 143.6
-13.9 7 44.6 17.2 63 145.4
-13.3 8 46.4 17.8 64 147.2
-12.8 9 48.2 18.3 65 149.0
-12.2 10 50.0 18.9 66 150.8
-11.7 11 51.8 19.4 67 152.6
-11.1 12 53.6 20.0 68 154.4
-10.6 13 55.4 20.6 69 156.2
-10.0 14 57.2 21.1 70 158.0
-9.44 15 59.0 21.7 71 159.8
-8.89 16 60.8 22.2 72 161.6
-8.33 17 62.6 22.8 73 163.4
-7.78 18 64.4 23.3 74 165.2
C - F TEMPERATURE
CONVERSIONS
The numbers in bold face type refer to the temperatures, either
in degrees Celsius (C) or degrees Fahrenheit (F). For example,
reading from centre to left, -150F is equivalent to -101C or from
centre to right -150C is equivalent to -238F and so on.
207
CONTENTS
C F C F
C F C F
-7.22 19 66.2 23.9 75 167.0
-6.67 20 68.0 24.4 76 168.8
-6.11 21 69.8 25.0 77 170.6
-5.56 22 71.6 25.6 78 170.4
-5.00 23 73.4 26.1 79 174.2
-4.44 24 75.2 26.7 80 176.0
-3.89 25 77.0 27.2 81 177.8
-3.33 26 78.8 27.8 82 179.6
-2.78 27 80.6 28.3 83 181.4
-2.22 28 82.4 29.4 84 183.2
-1.67 29 84.2 29.4 85 185.0
-1.11 30 86.0 30.0 86 186.8
-0.56 31 87.8 30.6 87 188.6
0 32 89.6 31.1 88 190.4
0.56 33 91.4 31.7 89 192.2
1.11 34 93.2 32.2 90 194.0
1.67 35 95.0 32.8 91 195.8
2.22 36 69.8 33.3 92 197.6
2.78 37 98.6 33.9 93 199.4
3.33 38 100.4 34.4 94 201.2
3.89 39 102.2 35.0 95 203.0
4.44 40 104.0 35.6 96 204.8
TEMPERATURE CONVERSION FORMULAE:
C =
5
x (F - 32)

F =
9
x C + 32

9

5
208
CONTENTS
C - F TEMPERATURE
CONVERSIONS
C F C F
C F C F
36.1 97 206.6 277 530 986
36.7 98 208.4 382 540 1004
37.2 99 210.2 288 550 1022
38 100 212 293 560 1040
43 110 230 299 570 1058
49 120 248 304 580 1076
54 130 266 310 590 1094
60 140 284 316 600 1112
66 150 302 321 610 1130
71 160 320 327 620 1148
77 170 338 332 630 1166
82 180 356 338 640 1184
88 190 374 343 650 1202
93 200 392 349 660 1220
99 210 410 354 670 1238
100 212 413 360 680 1256
104 220 428 366 690 1274
110 230 446 371 700 1292
116 240 464 377 710 1310
121 250 482 382 720 1328
127 260 500 388 730 1346
132 270 518 393 740 1364
138 280 536 399 750 1382
143 290 554 404 760 1400
149 300 572 410 770 1418
154 310 590 416 760 1436
160 320 608 421 790 1454
166 330 626 427 800 1472
171 340 644 432 810 1490
177 350 662 438 820 1508
182 380 680 443 830 1526
188 370 698 449 840 1544
193 380 716 454 850 1562
199 390 734 460 860 1580
The numbers in bold face type refer to the temperatures, either
in degrees Celsius (C) or degrees Fahrenheit (F). For example,
reading from centre to left, -100F is equivalent to -38C or from
centre to right -100C is equivalent to -212F and so on.
209
CONTENTS
S
I

U
N
I
T
S

A
N
D

C
O
N
V
E
R
S
I
O
N

D
A
T
A

C F C F
C F C F
204 400 752 466 870 1598
210 410 770 471 880 1616
216 420 788 477 890 1634
221 430 806 482 900 1652
227 440 824 488 910 1670
232 450 842 493 920 1688
238 460 860 499 930 1706
243 470 878 504 940 1424
249 480 896 510 950 1742
254 490 914 516 960 1760
260 500 932 521 970 1778
266 510 950 527 980 1796
271 520 968 532 990 1814
538 1000 1832
TEMPERATURE CONVERSION FORMULAE:
C =
5
x (F - 32)

F =
9
x C + 32

9

5
210
CONTENTS
COMPARISON OF
HARDNESS SCALES
ROCKWELL
Hardness No.
C Scale
(HRc)
VICKERS
Hardness No.
(Diamond
Pyramid)
(HV 30)
MM
PER MIN
Hardness No.
(3000kg/10mm
WC ball) (HB)
APPROXIMATE
TENSILE
STRENGTH (MPa)
68.0 940 - -
66.4 880 767 -
64.0 800 722 -
62.5 760 698 -
60.0 697 653 -
58.8 670 630 2,239
57.3 640 601 2,131
55.6 607 570 2,020
53.5 569 534 1,887
52.1 547 541 1,813
50.3 516 485 1,703
49.6 508 477 1,675
47.1 472 444 1,544
45.7 455 429 1,496
44.5 440 415 1,447
41.8 410 388 1,351
40.4 396 375 1,294
37.9 372 352 1,214
36.6 360 341 1,172
35.5 350 331 1,144
34.3 339 321 1,102
33.1 328 311 1,068
32.1 319 302 1,034
30.9 309 293 999
29.9 301 285 971
28.8 292 277 945
26.6 276 262 889
24.2 261 248 841
22.8 253 241 814
20.5 241 229 766
(18.8) 234 223 745
(15.2) 218 207 689
(10.0) 196 187 621
(6.4) 182 174 585
(0.9) 163 156 523
- 143 137 462
- 122 116 400
- 117 111 386
Value in brackets are beyond normal range.
Figures are approx. Actual values to be substantiated by measurement.
211
CONTENTS
S
I

U
N
I
T
S

A
N
D

C
O
N
V
E
R
S
I
O
N

D
A
T
A

STRESS AND ENERGY
CONVERSIONS
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
120
110
100
90
80
70
60
50
40
30
20
10
0
STRESS CONVERSIONS
IMPACT ENERGY
CONVERSIONS
MPa tonf/in
lbf/in

(x 1000)
kgfm kgf/mm
Joules ft lb
1400
1350
1300
1250
1200
1150
1100
1050
1000
950
900
850
800
750
700
650
600
550
500
450
400
350
300
250
200
150
100
50
0
200
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
140
135
130
125
120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
212
CONTENTS
WIRE AND SHEET SIZES
T
H
I
C
K
N
E
S
S

O
F

D
I
A
M
E
T
E
R
,

X
B
I
R
M
I
N
G
H
A
M

G
A
U
G
E

(
B
/
G
.
)
S
H
E
E
T

O
R

P
L
A
T
E

O
F

T
H
I
C
K
N
E
S
S
,

X
.

k
g
/
i
n
I
M
P
E
R
I
A
L

S
T
A
N
D
A
R
D

O
F

W
I
R
E

G
A
U
G
E

(
S
W
G
)
W
I
R
E

O
R

R
O
D

D
I
A
M
E
T
E
R
,

X

K
g
/
5
0
m
I
N
C
H
E
S

(
D
e
c
i
m
a
l
)
I
N
C
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S

(
F
r
a
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s
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M
M
0
.
0
1
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1
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6
4
0
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3
9
7
2
8
3
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9
0
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4
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.
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6
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4
.
4
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6
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.
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4
7
-
0
.
6
2
8
2
4
4
.
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1
2
2
0
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2
8
-
0
.
7
1
1
-
5
.
6
2
2
.
1
5
6
0
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0
3
1
2
5
1
/
3
2
0
.
7
9
4
2
2
6
.
2
-
.
1
9
4
0
.
0
3
6
-
0
.
9
1
4
-
7
.
2
2
0
.
2
5
8
0
.
0
3
9
2
-
0
.
9
9
6
2
0
7
.
8
-
.
3
0
2
0
.
0
3
9
3
7
-
1
.
0
-
7
.
9
-
.
3
0
8
0
.
0
4
6
8
7
5
3
/
6
4
1
.
1
9
1
-
9
.
3
-
.
4
3
7
0
.
0
4
8
-
1
.
2
2
-
9
.
6
1
8
.
4
5
9
0
.
4
9
5
-
1
.
2
6
1
8
9
.
9
-
.
4
8
9
0
.
0
5
9
-
1
.
5
-
1
1
.
8
-
.
6
9
4
0
.
0
6
2
5
1
/
6
1
.
5
8
8
1
6
1
2
.
5
-
.
7
7
7
0
.
0
6
4
-
1
.
6
3
-
1
2
.
8
1
6
.
8
1
9
0
.
0
7
8
5
-
1
.
9
9
1
4
1
5
.
6
-
1
.
2
2
0
.
0
7
8
7
-
2
.
0
-
1
5
.
7
-
1
.
2
3
0
.
0
8
0
-
2
.
0
3
-
1
5
.
9
1
4
1
.
2
7
0
.
0
9
8
4
-
2
.
5
-
1
9
.
6
-
1
.
9
3
0
.
0
9
9
1
-
2
.
5
2
1
2
1
9
.
8
-
1
.
9
6
0
.
1
0
4
-
2
.
6
4
-
2
0
.
7
1
2
2
.
1
5
0
.
1
1
8
-
3
.
0
-
2
3
.
6
-
2
.
7
7
0
.
1
2
5
0
1
/
8
3
.
1
7
5
1
0
2
4
.
9
-
3
.
1
1
0
.
1
2
8
-
3
.
2
5
-
2
5
.
5
1
0
3
.
2
6
0
.
1
3
8
-
3
.
5
-
2
7
.
5
-
3
.
7
8
213
CONTENTS
S
I

U
N
I
T
S

A
N
D

C
O
N
V
E
R
S
I
O
N

D
A
T
A

N
O
T
E
:

T
h
e

B
i
r
m
i
n
g
h
a
m

G
a
u
g
e

i
s

g
e
n
e
r
a
l
l
y

e
m
p
l
o
y
e
d

f
o
r

u
n
c
o
a
t
e
d

p
l
a
i
n

c
a
r
b
o
n

s
t
e
e
l

s
h
e
e
t
.

T
h
e

I
m
p
e
r
i
a
l

S
t
a
n
d
a
r
d

W
i
r
e

G
a
u
g
e

(
S
W
G
)

i
s

c
o
m
m
o
n
l
y

u
s
e
d

f
o
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a
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s
t
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(
i
n
c
.

s
t
a
i
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)

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w
i
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s
.

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t

i
s

a
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e
d

f
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s
t
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s
s

s
t
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l
,

a
l
u
m
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n
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a
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d

o
t
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n
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f
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s
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t
s

a
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t
u
b
e
s
.
T
H
I
C
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S
S

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A
M
E
T
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R
,

X
B
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M
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G
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U
G
E

(
B
/
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.
)
S
H
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T

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O
F

T
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,

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.

k
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(
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I
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(
D
e
c
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l
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I
N
C
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E
S

(
F
r
a
c
t
i
o
n
s
)
M
M
0
.
1
5
7
5
/
3
2
4
.
0
8
3
1
.
4
-
4
.
9
3
0
.
1
6
0
-
4
.
0
7
-
3
1
.
9
8
5
.
1
1
0
.
1
7
7
-
4
.
5
-
3
5
.
3
-
6
.
2
4
0
.
1
8
7
5
3
/
1
6
4
.
7
6
2
-
3
7
.
4
-
6
.
9
9
0
.
1
9
2
-
4
.
8
8
-
3
8
.
3
6
7
.
3
4
0
.
1
9
6
9
-
5
.
0
-
3
9
.
3
-
7
.
7
1
0
.
2
3
2
-
5
.
8
9
-
4
6
.
2
4
1
0
.
6
9
0
.
2
3
6
2
-
6
.
0
-
4
7
.
1
-
1
1
.
1
0
0
.
2
5
1
/
4
6
.
3
5
-
4
9
.
8
-
1
2
.
4
3
0
.
2
7
5
6
-
7
.
0
-
5
5
.
0
2
1
5
.
1
1
0
.
3
0
0
-
7
.
6
2
-
5
9
.
8
1
1
7
.
9
0
0
.
3
1
2
5
5
/
1
6
7
.
9
3
8
-
6
2
.
3
-
1
9
.
4
2
0
.
3
1
5
0
-
8
.
0
-
6
2
.
3
-
1
9
.
4
2
0
.
3
2
4
-
8
.
2
3
-
6
4
.
6
0
2
0
.
8
8
0
.
3
5
4
3
-
9
.
0
-
7
0
.
7
-
2
4
.
9
7
0
.
3
7
5
3
/
8
9
.
5
2
5
-
7
4
.
8
-
2
7
.
9
7
0
.
3
9
3
7
-
1
0
.
0
-
7
8
.
5
-
3
0
.
8
3
0
.
5
1
/
2
1
2
.
7
0
0
-
9
9
.
7
-
4
9
.
7
2
0
.
6
2
5
5
/
8
1
5
.
8
7
5
-
1
2
4
.
6
-
7
7
.
6
9
0
.
7
5
3
/
4
1
9
.
0
5
0
-
1
4
9
.
5
-
1
1
1
.
8
7
0
.
8
7
5
7
/
8
2
2
.
2
3
0
-
1
7
4
.
5
-
1
5
2
.
3
4
1
.
0
-
2
5
.
4
0
0
-
1
9
9
.
4
-
1
9
8
.
8
8
214
CONTENTS
SYMBOLS FOR ELEMENTS
AND GEOMETRIC FORMULAE
SYMBOL FOR ELEMENTS
Al Aluminium
B Boron
C Carbon
Cb Columbium
Cd Cadmium
Co Cobalt
Cr Chromium
Sn Tin
V Vanadium
Cu Copper
H Hydrogen
Fe Iron
Mg Magnesium
Mn Manganese
Mo Molybdenum
N Nitrogen
Ta Tantalum
W Tungsten
Nb Niobium
Ni Nickel
O Oxygen
P Phosphorus
Pb Lead
S Sulphur
Si Silicon
Ti Titanium
Zn Zinc
Columbium (Cb) is commonly know as Niobium (Nb).
GEOMETRIC FORMULAE
LENGTHS:
Circumference of a circle = x diameter of circle
Arc of a circle = .01745 x angle of arc, in degrees.
AREAS:
Triangle = 1/2 base x perpendicular height
Circle = .7854 x square of diameter = x square of radius
Ellipse = .7854 x long axis x short axis
Parabola = 2/3 base x height
Square = square of the side
Rhomboid or Rhombus = base x height
Parallelogram = base x height
Sector of a circle = 1/2 radius x length of arc
Polygon (regular) = 1/2 radius of inscribed circle x length of
one side x number of sides
VOLUMES:Cone = 1/3 area of circle x perpendicular height
Cylinder = area of circle x height
Prism = area of base x height
Pyramid = 1/3 area of base x perpendicular height
Sphere = 4.1783 x radius cubed
215
CONTENTS
S
Y
M
B
O
L
S

F
O
R

E
L
E
M
E
N
T
S

A
N
D

G
E
O
M
E
T
R
I
C

F
O
R
M
U
L
A
E
NOTES
216
CONTENTS
NOTES
217
CONTENTS
Certied Quality
Management System
WIA is ISO 9001 certied.
Its your guarantee of the
highest levels of quality,
satisfaction and efciency
when you choose WIA.
Technical data sheets
and MSDS sheets are
available to download
at welding.com.au
WEB
VISIT US ON THE
WELDING.COM.AU
Welding Industries of Australia
A Division of ITW Australia Pty Ltd ABN 63 004 235 063
Tel 1300 300 884 Fax 1300 301 884
welding.com.au

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1

. Arc transfer characteristics are

Yield Stress 460 MPa 480 MPa

or Argon based gas

Yield Stress 560 MPa 570 MPa

Yield Stress 732 MPa

), will result in higher alloy recovery

shielding gas mixture. Weld beads are almost

Yield Stress 628 MPa

shielding gas at a fow rate of 15-20 litres/minute.

Yield Stress 531 MPa

shielding gas mixtures.

Yield Stress 487 MPa

Yield Stress 503 MPa

Yield Stress 533 MPa

0.04 1.02 0.29 0.010 0.007 2.09

0.05 1.26 0.44 0.010 0.007 2.07

WELDING - Gas Metal-Arc welding using CO

FIGURE 4 ACTUAL AND DESIGN

Desired weld Section A-A

mixtures may be preferred. Most popular group.

) of 8 mm and a root radius (r) of 10 mm, the

+ r) = 60 - 18 = 42 mm. The width of the rectangle (w) is of

shielding gas is used

Shielding Gas Consumption

gas consumption let us assume, the 1.6mm

fow rate of 12 L/min approximately 0.13m

gas will be consumed per kg of weld metal deposited (see

and SAW process

is 4.15 x .30 = 1.25 metres of joint/hour, and the welding

shielding gas required.NB. 1m

at 15.6C and 1 atmosphere has a mass of 1.87 kg. 1m

shielding gas required.

at 15.6C and 1 atmosphere has a mass of 1.87 kg.

= .3861 sq mile 1 sq mile = 2.5899 km

= .2200 gal 1 gal = 4.5461 dm

= 0.2642 US gal 1 US gal = 3.7854 dm

MASS: 1 kg = 35.2740 oz 1 oz = 28.3495 g

/hr = 0.472 L/min

/hr = 0.125 US gal/min 1 US gal/min = 8.021 ft

, more popularly known as the pascal (symbol Pa). One

or MPa, are frequently used. In the metric

whilst the imperial system

(TSI) and lbf/in

(psi) to defne stress.

(TSI) 1TSI = 15.456 MPa

(psi) 1 psi = .0069 MPa

. The pound per cubic inch, lb/in

, and the pound

are units frequently used in the imperial system.

= 36.1273 x 10-6 lb/in

Some weld metal densities worth noting are:

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